2008 YAMAHA TW200 wheel

PERIODIC MAINTENANCE AND MINOR REPAIR
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brake fluid level goes down sud-
denly, have a Yamaha dealer
check the cause.

EAU22720
Changing the brake fluid
Have a Yamaha dealer change the
brake fluid at the intervals specified in
the NOTE after the periodic mainte-
nance and lubrication chart. In addition,
have the oil seals of the brake master
cylinder and caliper as well as the
brake hose replaced at the intervals
listed below or whenever they are dam-
aged or leaking.

Oil seals: Replace every two
years.

Brake hose: Replace every four
years.
EAU22760
Drive chain slack
The drive chain slack should be
checked before each ride and adjusted
if necessary.
EAU22770
To check the drive chain slack
1. Place the motorcycle on a level
surface and hold it in an upright po-
sition.
NOTE:

When checking and adjusting the drive
chain slack, the motorcycle should be
positioned straight up and there should
be no weight on it.
2. Shift the transmission into the neu-
tral position.
3. Move the rear wheel by pushing
the motorcycle to locate the tight-
est portion of the drive chain, and
then measure the drive chain slack
as shown.
Drive chain slack:
35.0–60.0 mm (1.38–2.36 in)

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4. If the drive chain slack is incorrect,
adjust it as follows.

EAU22830
To adjust the drive chain slack
1. Loosen the brake pedal free play
adjusting nut.2. Loosen the axle nut.
3. To tighten the drive chain, turn the
adjusting plate on each side of the
swingarm in direction (a). To loos-
en the drive chain, turn the adjust-
ing plate on each side of the
swingarm in direction (b), and then
push the rear wheel forward.
NOTE:

Make sure that both adjusting plates
are in the same position for proper
wheel alignment.
CAUTION:

ECA10570
Improper drive chain slack will over-
load the engine as well as other vital
parts of the motorcycle and can lead
to chain slippage or breakage. To
prevent this from occurring, keep
the drive chain slack within the
specified limits.
4. Tighten the axle nut to the speci-
fied torque.
5. Adjust the brake pedal free play.
(See page 6-18.)
WARNING

EWA10660
After adjusting the brake pedal free
play, check the operation of the
brake light.
1. Drive chain slack
1

1. Brake pedal free play adjusting nut
2. Axle nut
3. Adjusting plate32
1
(a)
(b)
Tightening torque:
Axle nut:
90 Nm (9.0 m·kgf, 65 ft·lbf)

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CAUTION:

ECA10590
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or re-
pair it.
EAU23280
Checking the steering
Worn or loose steering bearings may
cause danger. Therefore, the operation
of the steering must be checked as fol-
lows at the intervals specified in the pe-
riodic maintenance and lubrication
chart.
1. Place a stand under the engine to
raise the front wheel off the
ground.
WARNING

EWA10750
Securely support the vehicle so that
there is no danger of it falling over.
2. Hold the lower ends of the front
fork legs and try to move them for-
ward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the steering.

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EAU23290
Checking the wheel bearings
The front and rear wheel bearings must
be checked at the intervals specified in
the periodic maintenance and lubrica-
tion chart. If there is play in the wheel
hub or if the wheel does not turn
smoothly, have a Yamaha dealer check
the wheel bearings.
EAU23361
Battery
A poorly maintained battery will corrode
and discharge quickly. The electrolyte
level, battery lead connections and
breather hose routing should be
checked before each ride and at the in-
tervals specified in the periodic mainte-
nance and lubrication chart.
To check the electrolyte level
1. Remove the seat. (See page 3-8.)
2. Disconnect the negative battery
lead from the battery.
3. Disconnect the positive battery
lead and the battery breather hose
from the battery.
4. Unhook the battery band, and then
pull the battery out of the battery
compartment.5. Place the battery on a level sur-
face, and then check the electro-
lyte level in the battery.
NOTE:

The electrolyte should be between the
minimum and maximum level marks.
1. Battery
2. Negative battery lead
3. Positive battery lead (red)
4. Battery breather hose
5. Battery band
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CAUTION:

ECA10680
Do not overtighten the screws, oth-
erwise the lens may break.
EAU24350
Supporting the motorcycle
Since this model is not equipped with a
centerstand, follow these precautions
when removing the front and rear
wheel or performing other maintenance
requiring the motorcycle to stand up-
right. Check that the motorcycle is in a
stable and level position before starting
any maintenance. A strong wooden
box can be placed under the engine for
added stability.
To service the front wheel
1. Stabilize the rear of the motorcycle
by using a motorcycle stand or, if
an additional motorcycle stand is
not available, by placing a jack un-
der the frame in front of the rear
wheel.
2. Raise the front wheel off the
ground by using a motorcycle
stand.
To service the rear wheel
Raise the rear wheel off the ground by
using a motorcycle stand or, if a motor-
cycle stand is not available, by placing
a jack either under each side of theframe in front of the rear wheel or under
each side of the swingarm.

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EAU24360
Front wheel
EAU24580
To remove the front wheel
WARNING

EWA10820

It is advisable to have a Yamaha
dealer service the wheel.

Securely support the motorcy-
cle so that there is no danger of
it falling over.
1. Disconnect the speedometer ca-
ble from the front wheel.
2. Loosen the axle nut.
3. Lift the front wheel off the ground
according to the procedure onpage 6-33.
4. Remove the axle nut, pull the
wheel axle out, and then remove
the wheel.
CAUTION:

ECA11070
Do not apply the brake after the
wheel has been removed together
with the brake disc, otherwise the
brake pads will be forced shut.
EAU24981
To install the front wheel
1. Install the speedometer gear unit
into the wheel hub so that the pro-
jections mesh with the slots.
2. Lift the wheel up between the fork
legs.
NOTE:

Make sure that there is enough space
between the brake pads before insert-
ing the brake disc and that the slot in
the speedometer gear unit fits over the
retainer on the fork leg.3. Insert the wheel axle, and then in-
stall the axle nut.
4. Lower the front wheel so that it is
on the ground.
5. Tighten the axle nut to the speci-
fied torque.
6. Connect the speedometer cable.
1. Speedometer cable
2. Axle nut
1
2

1. Retainer
2. Speedometer cable
Tightening torque:
Axle nut:
90 Nm (9.0 m·kgf, 65 ft·lbf)
2 1

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EAU25080
Rear wheel
EAU25420
To remove the rear wheel
WARNING

EWA10820

It is advisable to have a Yamaha
dealer service the wheel.

Securely support the motorcy-
cle so that there is no danger of
it falling over.
1. Loosen the axle nut.
2. Remove the brake pedal free playadjusting nut, and then disconnect
the brake rod from the brake cam-
shaft lever.
3. Turn the drive chain adjusting
plate on each side of the swingarm
fully in direction (a).
4. Lift the rear wheel off the ground
according to the procedure on
page 6-33.
5. Remove the axle nut, and then pull
the wheel axle out.
6. Push the wheel forward, and then
remove the drive chain from the
rear sprocket.
NOTE:

The drive chain does not need to be
disassembled in order to remove and
install the wheel.
7. Remove the wheel.
EAU25761
To install the rear wheel
1. Insert the wheel axle from the
left-hand side.
NOTE:

Make sure that the drive chain adjust-
ing plates are installed with thepunched sides facing to the outside
and that the slot in the brake shoe plate
fits over the retainer on the swingarm.
2. Install the drive chain onto the rear
sprocket, and then adjust the drive
chain slack. (See page 6-21.)
3. Install the axle nut, and then lower
the rear wheel so that it is on the
ground.
4. Tighten the axle nut to the speci-
fied torque.
1. Axle nut
2. Brake pedal free play adjusting nut
3. Brake rod
4. Brake camshaft lever
5. Drive chain slack adjusting plate
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(a)

1. Retainer
Tightening torque:
Axle nut:
90 Nm (9.0 m·kgf, 65 ft·lbf)
1

MOTORCYCLE CARE AND STORAGE
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EAU26000
Care
While the open design of a motorcycle
reveals the attractiveness of the tech-
nology, it also makes it more vulnera-
ble. Rust and corrosion can develop
even if high-quality components are
used. A rusty exhaust pipe may go un-
noticed on a car, however, it detracts
from the overall appearance of a motor-
cycle. Frequent and proper care does
not only comply with the terms of the
warranty, but it will also keep your mo-
torcycle looking good, extend its life
and optimize its performance.
Before cleaning
1. Cover the muffler outlet with a
plastic bag after the engine has
cooled down.
2. Make sure that all caps and covers
as well as all electrical couplers
and connectors, including the
spark plug cap, are tightly in-
stalled.
3. Remove extremely stubborn dirt,
like oil burnt onto the crankcase,
with a degreasing agent and abrush, but never apply such prod-
ucts onto seals, gaskets, sprock-
ets, the drive chain and wheel
axles. Always rinse the dirt and de-
greaser off with water.
Cleaning
CAUTION:

ECA10770

Avoid using strong acidic wheel
cleaners, especially on spoked
wheels. If such products are
used on hard-to-remove dirt, do
not leave the cleaner on the af-
fected area any longer than in-
structed. Also, thoroughly rinse
the area off with water, immedi-
ately dry it, and then apply a cor-
rosion protection spray.

Improper cleaning can damage
windshields, cowlings, panels
and other plastic parts. Use only
a soft, clean cloth or sponge
with mild detergent and water to
clean plastic.

Do not use any harsh chemical
products on plastic parts. Be
sure to avoid using cloths orsponges which have been in
contact with strong or abrasive
cleaning products, solvent or
thinner, fuel (gasoline), rust re-
movers or inhibitors, brake flu-
id, antifreeze or electrolyte.

Do not use high-pressure wash-
ers or steam-jet cleaners since
they cause water seepage and
deterioration in the following ar-
eas: seals (of wheel and swing-
arm bearings, fork and brakes),
electric components (couplers,
connectors, instruments,
switches and lights), breather
hoses and vents.

For motorcycles equipped with
a windshield: Do not use strong
cleaners or hard sponges as
they will cause dulling or
scratching. Some cleaning com-
pounds for plastic may leave
scratches on the windshield.
Test the product on a small hid-
den part of the windshield to
make sure that it does not leave