Page 1
Read this manual carefully before operating this vehicle. OWNER’S MANUAL TW200B TW200BC LIT-11626-25-04 10D-28199-15...
Page 2
EAU10042 Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold.
Page 3
Yamaha has met these standards without reducing the performance or economy of operation of the motorcycle. To maintain these high standards, it is important that you and your Yamaha dealer pay close attention to the recommended maintenance schedules and operating instructions contained within this manual.
IMPORTANT MANUAL INFORMATION EAU10132 Particularly important information is distinguished in this manual by the following notations: This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.
TABLE OF CONTENTS FOR YOUR SAFETY – LOCATION OF IMPORTANT Checking the throttle grip free LABELS ..........1-1 PRE-OPERATION CHECKS ..... 5-1 play ..........7-17 Valve clearance ......7-18 SAFETY INFORMATION ....2-1 OPERATION AND IMPORTANT RIDING Tires ..........7-18 POINTS ..........
Page 7
Checking the wheel bearings ..7-31 MOTORCYCLE LIMITED Battery .......... 7-31 WARRANTY ......10-7 Replacing the fuse ......7-33 YAMAHA EXTENDED SERVICE Replacing the headlight bulb ..7-34 (Y.E.S.) ........10-9 Replacing the tail/brake light bulb ........... 7-35 Replacing a turn signal light bulb ...........
Read and understand all of the labels on your vehicle. They contain important information for safe and proper operation of your vehicle. Never remove any labels from your vehicle. If a label becomes difficult to read or comes off, a replacement label is available from your Yamaha dealer. 3, 4, 5...
Page 9
LOCATION OF IMPORTANT LABELS WARNING LOAD LIMIT BEFORE YOU OPERATE THIS VEHICLE, READ 3 kg {7 lbs} THE OWNER’S MANUAL AND ALL LABELS. 3TB-24877-A0 ALWAYS WEAR AN APPROVED MOTORCYCLE HELMET, eye protection, and protective clothing. 5GK-2118K-00 2 California only WARNING This unit contains high pressure nitrogen gas.
Page 11
LOCATION OF IMPORTANT LABELS Read owner’s manual before servicing battery. Electrolyte will damage metal parts or paint. If electrolyte spills, wash area with fresh water immediately. Be sure to connect breather hose after installing battery. 10D-2815N-00...
SAFETY INFORMATION EAU1031A Safe Riding see you. Avoid riding in another Perform the pre-operation checks each motorist’s blind spot. time you use the vehicle to make sure it Many accidents involve inexperi- Be a Responsible Owner is in safe operating condition. Failure to enced operators.
Page 13
SAFETY INFORMATION ed by road and traffic conditions. Always wear an approved helmet. less, tasteless gas which may be • Always signal before turning or Wear a face shield or goggles. present even if you do not see or smell changing lanes.
Page 14
Yamaha accessories, which are avail- of the motorcycle is changed. To avoid to minimize imbalance or instabili- able only from a Yamaha dealer, have the possibility of an accident, use ex- been designed, tested, and approved ...
Page 15
SAFETY INFORMATION of the vehicle’s design or operation the motorcycle due to aerody- ing, and comfort. Other tires, rims, siz- characteristics can put you and others namic effects. Wind may at- es, and combinations may not be at greater risk of serious injury or death. tempt to lift the motorcycle, or appropriate.
Page 16
SAFETY INFORMATION parts that could break). Choose the location for the straps carefully so the straps will not rub against painted surfaces during transport. The suspension should be com- pressed somewhat tie-downs, if possible, so that the motorcycle will not bounce exces- sively during transport.
INSTRUMENT AND CONTROL FUNCTIONS EAU10460 EWA10061 1. Turn the handlebars all the way to Main switch/steering lock WARNING the left or right. Never turn the key to “OFF” or 2. Push the key in from the “OFF” po- “LOCK” while the vehicle is moving. sition, release it, and then turn it to Otherwise the electrical systems will “LOCK”.
INSTRUMENT AND CONTROL FUNCTIONS EAU10981 high beam of the headlight is switched EAU11630 Indicator lights Speedometer unit 1. Turn signal indicator light “ ” 1. Speedometer 2. High beam indicator light “ ” 2. Odometer 3. Neutral indicator light “ ”...
INSTRUMENT AND CONTROL FUNCTIONS EAU12348 Right EAU12500 Handlebar switches Horn switch “ ” Press this switch to sound the horn. Left EAU12660 Engine stop switch “ ” Set this switch to “ ” before starting the engine. Set this switch to “ ”...
INSTRUMENT AND CONTROL FUNCTIONS EAU12820 EAU12871 EAU12890 Clutch lever Shift pedal Brake lever 1. Clutch lever 1. Shift pedal 1. Brake lever The clutch lever is located at the left The shift pedal is located on the left The brake lever is located at the right handlebar grip.
INSTRUMENT AND CONTROL FUNCTIONS EAU12941 EAU32281 Brake pedal Fuel tank cap The fuel tank cap cannot be installed unless the key is in the lock. In addition, the key cannot be removed if the cap is not properly installed and locked. EWA10121 WARNING Make sure that the fuel tank cap is...
EWA15151 as well as to the exhaust system. WARNING bottom of the filler tube. Because Your Yamaha engine has been de- fuel expands when it heats up, Gasoline is poisonous and can signed to use regular unleaded gaso- heat from the engine or the sun cause injury or death.
10% (E10). Gas- ohol containing methanol recommended by Yamaha because it 1. Arrow mark positioned over “ON” can cause damage to the fuel system or vehicle performance problems. With the lever in this position, fuel flows FUEL to the carburetor.
INSTRUMENT AND CONTROL FUNCTIONS This indicates reserve. If you run out of EAU13600 EAU13971 Starter (choke) knob “ ” Seat fuel while riding, move the lever to this position. Fill the tank at the first oppor- To remove the seat tunity.
Do not dispose of a damaged or causing loss of control and possibly worn-out shock absorber as- an accident. [EWA10161] sembly yourself. Take the shock absorber assembly to a Yamaha dealer for any service.
1. Carrier and distract the operator, resulting in a possible loss of control. Yamaha’s ignition circuit cut-off system has been designed to assist the operator in fulfilling the respon- sibility of raising the sidestand be- fore starting off.
INSTRUMENT AND CONTROL FUNCTIONS Yamaha dealer repair it if it does not EAU15314 Ignition circuit cut-off system function properly. The ignition circuit cut-off system (com- prising the sidestand switch, clutch switch and neutral switch) has the fol- lowing functions. ...
Page 31
INSTRUMENT AND CONTROL FUNCTIONS WARNING With the engine turned off: 1. Move the sidestand down. If a malfunction is noted, have a Yamaha 2. Make sure that the engine stop switch is set to “ ”. dealer check the system before riding.
Engine oil 7-12 • Check vehicle for oil leakage. • Check operation. • If soft or spongy, have Yamaha dealer bleed hydraulic system. • Check lever free play. • Adjust if necessary. • Check brake pads for wear. Front brake 7-21, 7-24 •...
Page 33
• Make sure that operation is smooth. • Check throttle grip free play. Throttle grip 7-17, 7-28 • If necessary, have Yamaha dealer adjust throttle grip free play and lubricate cable and grip housing. • Make sure that operation is smooth. Control cables 7-27 •...
Tempera- light should come on. If not, ask a tures above 10 C (50 F) require about Yamaha dealer to check the elec- 7 seconds of starter (choke) use and trical circuit. temperatures below 10 C (50 F) re- 4.
OPERATION AND IMPORTANT RIDING POINTS ECA11042 EAU16640 EAU16671 Starting a warm engine Shifting NOTICE Follow the same procedure as for start- For maximum engine life, never ac- ing a cold engine with the exception celerate hard when the engine is that the starter (choke) is not required cold! when the engine is warm.
Page 36
OPERATION AND IMPORTANT RIDING POINTS the neutral position, do not quickly pull the clutch lever in. EAU16720 Recommended shift points coast for long periods of time 5. Shift the transmission into second The recommended shift points during with the engine off, and do not gear.
NOTICE: After 1000 km (600 mi) of operation, the engine oil must be changed, the oil filter element and the oil strainer cleaned. If any engine trouble should occur during the engine break-in period, immedi- ately have a Yamaha dealer check the vehicle. [ECA12712]...
However, de- any repair establishment or individual pending on the weather, terrain, geo- that is certified (if applicable). Yamaha death. See page 2-2 for more in- graphical location, and individual use, dealers are trained and equipped to...
From 19000 mi (31000 km) or 36 months, repeat the maintenance intervals starting from 7000 mi (11000 km) or 12 months. Items marked with an asterisk require special tools, data and technical skills, have a Yamaha dealer perform the service. EAU17581 Periodic maintenance chart for the emission control system...
Page 41
PERIODIC MAINTENANCE AND ADJUSTMENT INITIAL ODOMETER READINGS 600 mi 4000 mi 7000 mi 10000 mi 13000 mi 16000 mi ITEM ROUTINE (1000 km) (6000 km) (11000 km) (16000 km) (21000 km) (26000 km) 1 month 6 months 12 months 18 months 24 months 30 months •...
PERIODIC MAINTENANCE AND ADJUSTMENT EAU32165 General maintenance and lubrication chart INITIAL ODOMETER READINGS 600 mi 4000 mi 7000 mi 10000 mi 13000 mi 16000 mi ITEM ROUTINE (1000 km) (6000 km) (11000 km) (16000 km) (21000 km) (26000 km) 1 month 6 months 12 months 18 months...
Page 43
Every 300 mi (500 km) and after washing the motorcycle and riding in the rain or • Adjust and thoroughly lubricate Drive chain wet areas chain with Yamaha chain and cable lube. • Check bearing assemblies for looseness. • Moderately repack with lith- ...
Page 44
Engine oil strainer Front and rear brake • Check operation. 24 * switches • Apply Yamaha chain and cable Control and meter 25 * cables lube or engine oil thoroughly.
Page 45
PERIODIC MAINTENANCE AND ADJUSTMENT EAU17620 The air filter needs more frequent service if you are riding in unusually wet or dusty areas. Hydraulic brake system • When disassembling the master cylinder or caliper cylinder, always replace the brake fluid. Check the brake fluid level regularly and fill as required.
PERIODIC MAINTENANCE AND ADJUSTMENT EAU18722 To install the cowling Removing and installing the Place the cowling in the original posi- cowling and panels tion, and then install the screw. The cowling and panels shown need to be removed to perform some of the EAU32451 maintenance jobs described in this chapter.
PERIODIC MAINTENANCE AND ADJUSTMENT EAU19604 Checking the spark plug The spark plug is an important engine component, which is easy to check. Since heat and deposits will cause any spark plug to slowly erode, the spark plug should be removed and checked in accordance with the periodic mainte- nance and lubrication chart.
Page 48
Spark plug gap: ating improperly. Do not attempt to 0.6–0.7 mm (0.024–0.028 in) diagnose such problems yourself. In- stead, have a Yamaha dealer check To install the spark plug the vehicle. 1. Clean the surface of the spark plug 2. Check the spark plug for electrode...
PERIODIC MAINTENANCE AND ADJUSTMENT EAU19681 EAU19795 Canister (for California only) Engine oil and oil filter element The engine oil level should be checked before each ride. In addition, the oil must be changed and the oil filter ele- ment cleaned at the intervals specified in the periodic maintenance and lubri- cation chart.
Page 50
PERIODIC MAINTENANCE AND ADJUSTMENT removing the engine oil drain bolt, the O-ring, compression spring, and oil strainer will fall out. Take care not to lose these parts. [ECA11001] 1. Oil strainer 1. Oil filter element cover 2. Compression spring 2. Oil filter element drain bolt 3.
Page 51
PERIODIC MAINTENANCE AND ADJUSTMENT 7. Check the O-rings for damage and addition, do not use oils labeled Tightening torque: replace them if necessary. “ENERGY CONSERVING II” or Engine oil drain bolt: 8. Clean the oil filter element with sol- higher. 43 Nm (4.3 m·kgf, 31 ft·lbf) ...
Clean the air filter element more fre- Recommended oil: quently if you are riding in unusually Yamaha foam air filter oil or other wet or dusty areas. In addition, the air quality foam air filter oil filter check hose must be frequently checked and cleaned if necessary.
PERIODIC MAINTENANCE AND ADJUSTMENT EAU21236 use a wire brush to remove any Cleaning the spark arrester carbon deposits from the spark ar- The spark arrester should be cleaned rester portion of the tailpipe and in- at the intervals specified in the periodic side of the tailpipe housing.
Check the engine idling speed and, if tem, which requires very sophisticated necessary, have it corrected by a adjustment. Therefore, carburetor ad- Yamaha dealer. justments should be left to Yamaha Engine idling speed: dealer, who has the necessary profes- 1350–1550 r/min sional knowledge and experience.
125 kPa (1.25 kgf/cm , 18 psi) must be adjusted by a Yamaha dealer 90–179 kg (198–395 lb) (CAL) at the intervals specified in the periodic Tire air pressure 90–180 kg (198–397 lb) (U49): maintenance and lubrication chart.
Page 56
The tires must be checked before each model by Yamaha Motor Co., Ltd. high-quality product. ride. If the tire shows crosswise lines Ride at moderate speeds after (minimum tread depth), if the tire has a...
3. Rubber cover looseness or damage before each 4. Adjusting bolt ride. If any damage is found, have a Yamaha dealer replace the The clutch lever free play should mea- wheel. Do not attempt even the sure 10.0–15.0 mm (0.39–0.59 in) as smallest repair to the wheel.
3. Brake lever free play system. If there is air in the hy- 4. Rubber cover draulic system, have a Yamaha dealer bleed the system before The brake lever free play should mea- operating the motorcycle. Air in sure 5.0–8.0 mm (0.20–0.31 in) as...
2. Adjusting bolt WARNING direction (a). To decrease the brake 3. Brake pedal height It is advisable to have a Yamaha pedal free play, turn the adjusting nut in dealer make these adjustments. 3. Tighten the locknut. direction (b).
The operation of the shift pedal should After adjusting the drive chain be checked before each ride. If opera- slack or removing and installing tion is not smooth, have a Yamaha the rear wheel, always check the dealer check the vehicle. brake pedal free play.
Clean the filler cap before re- brake system for leakage. If the brake Have a Yamaha dealer change the moving. Use only DOT 4 brake fluid level goes down suddenly, have a brake fluid at the intervals specified in fluid from a sealed container.
2. Shift the transmission into the neu- To adjust the drive chain slack drive chain slack adjusting plate on tral position. Consult a Yamaha dealer before ad- each side of the swingarm in direc- 3. Measure the drive chain slack as justing the drive chain slack.
If a cable is damaged wet areas. Service the drive chain as or does not move smoothly, have a Tightening torque: follows. Yamaha dealer check or replace it. Axle nut: WARNING! Damage to the outer ECA10583 90 Nm (9.0 m·kgf, 65 ft·lbf)
Lithium-soap-based grease be checked before each ride. In addi- tion, the cable should be lubricated by a Yamaha dealer at the intervals speci- fied in the periodic maintenance chart. The throttle cable is equipped with a rubber cover. Make sure that the cover is securely installed.
The swingarm pivots must be lubricat- and the pedal pivot should be lubricat- sidestand pivot and metal-to-metal ed by a Yamaha dealer at the intervals ed if necessary. contact surfaces should be lubricated if specified in the periodic maintenance necessary.
Avoid any contact with 3. Disconnect the positive battery smoothly, have a Yamaha dealer check skin, eyes or clothing and al- lead and the battery breather hose the wheel bearings.
Page 69
PERIODIC MAINTENANCE AND ADJUSTMENT 1. Battery 1. Maximum level mark 1. Battery breather hose 2. Battery band 2. Minimum level mark 3. Battery breather hose 6. If the electrolyte is at or below the 4. Positive battery lead (red) minimum level mark, add distilled 5.
PERIODIC MAINTENANCE AND ADJUSTMENT tive (-) terminal. that the breather hose is properly EAU23503 Replacing the fuse 11. Install the seat. routed, in good condition, and not The fuse holder is located behind panel obstructed. NOTICE: B. (See page 7-9.) To store the battery breather hose is positioned in If the fuse is blown, replace it as fol-...
ECA10650 NOTICE 4. If the fuse immediately blows Take care not to damage the follow- again, have a Yamaha dealer ing parts: check the electrical system. Headlight bulb Do not touch the glass part of 1.
1. Screw then remove the burnt-out bulb. 8. Install the cowling. 2. Remove the burnt-out bulb by 9. Have a Yamaha dealer adjust the pushing it in and turning it counter- headlight beam if necessary. clockwise. 1. Headlight bulb holder 5.
PERIODIC MAINTENANCE AND ADJUSTMENT EAU24204 Replacing a turn signal light bulb 1. Remove the turn signal light lens by removing the screw. 1. Tail/brake light bulb 1. Turn signal light bulb 3. Insert a new bulb into the socket, 3. Insert a new bulb into the socket, push it in, and then turn it clock- push it in, and then turn it clock- wise until it stops.
PERIODIC MAINTENANCE AND ADJUSTMENT EAU24350 frame in front of the rear wheel or under EAU24360 Supporting the motorcycle Front wheel each side of the swingarm. Since this model is not equipped with a centerstand, follow these precautions EAU51400 To remove the front wheel when removing the front and rear EWA10821 wheel or performing other maintenance...
Page 75
PERIODIC MAINTENANCE AND ADJUSTMENT 4. Remove the axle nut and the washer. 5. Pull the wheel axle out. 6. Remove the spacer, speedometer gear unit and the wheel. NOTICE: Do not apply the brake after the wheel has been removed to- gether with the brake disc, oth- erwise the brake pads will be forced shut.
PERIODIC MAINTENANCE AND ADJUSTMENT EAU25080 8. Remove the spacers, the drive Rear wheel chain slack adjusting plates and the wheel. EAU51421 To remove the rear wheel EAU51431 EWA10821 To install the rear wheel WARNING 1. Insert the spacers. To avoid injury, securely support the 2.
5. Install the axle nut. self. However, should your motorcycle 6. Adjust the drive chain slack. (See require any repair, take it to a Yamaha page 7-26.) dealer, whose skilled technicians have 7. Lower the rear wheel so that it is the necessary tools, experience, and on the ground.
Page 78
PERIODIC MAINTENANCE AND ADJUSTMENT heaters or furnaces. Gasoline or gasoline vapors can ignite or ex- plode, causing severe injury or property damage. 7-41...
Remove the spark plug and check the electrodes. The engine does not start. Have a Yamaha dealer check the vehicle. Check the battery. 4. Battery The engine turns over The battery is good.
Be ble. Rust and corrosion can develop Cleaning sure to consult a Yamaha dealer for even if high-quality components are ECA10772 advice on what products to use be- NOTICE used.
Page 81
MOTORCYCLE CARE AND STORAGE off any detergent residue using Test the product on a small hid- remain well into spring. plenty of water, as it is harmful den part of the windshield to 1. Clean the motorcycle with cold wa- to plastic parts.
EWA11131 WARNING Consult a Yamaha dealer for ad- ECA10810 NOTICE vice on what products to use. Contaminants on the brakes or tires ...
Page 83
MOTORCYCLE CARE AND STORAGE than 0 C (30 F) or more than 30 fuel cock that has an “OFF” posi- age or injury from sparking, C (90 F)]. For more information tion: Turn the fuel cock lever to make sure to ground the “OFF”.
Record the key identification number, vehicle identification number and mod- el label information in the spaces pro- vided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehi- cle is stolen. KEY IDENTIFICATION NUMBER: 1.
Page 88
This label shows specifica- spare parts from a Yamaha dealer. tions related to exhaust emissions as required by federal law, state law and Environment Canada.
If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Yamaha Motor Corporation, U.S.A. If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign.
CONSUMER INFORMATION EAU26560 Motorcycle noise regulation TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or element of design incorporated into any new ve- hicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.
CONSUMER INFORMATION EAU26611 Maintenance record Copies of work orders and/or receipts for parts purchased and installed on your motorcycle will be required to document that maintenance has been completed in accordance with the emissions warranty. The chart below is printed only as a reminder that maintenance work is required.
Page 92
CONSUMER INFORMATION Maintenance Date of Servicing dealer Mileage Remarks interval service name and address 28000 mi (46000 km) or 54 months 31000 mi (51000 km) or 60 months 10-6...
CONSUMER INFORMATION EAU26663 YAMAHA MOTOR CORPORATION, U.S.A. STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY Yamaha Motor Corporation, U.S.A. hereby warrants that CUSTOMER’S RESPONSIBILITY under this Engine new Yamaha motorcycles will be free from defects in warranty shall be to: Displacement Period...
Page 94
CUSTOMER SERVICE What costs are my responsibility during the warranty period? If your machine requires warranty service, you must take it to any authorized Yamaha The customer’s responsibility includes all costs of normal maintenance services, motorcycle dealer within the continental United States. Be sure to bring your warranty non-warranty repairs, accident and collision damages, and oil, oil filters, air filters, registration card or other valid proof of the original date of purchase.
This excellent Y.E.S. plan coverage is only available to dealer to see how comforting uninterrupted factory- Yamaha owners like you, and only while your Yamaha is still backed protection can be. within the Yamaha Limited Warranty period. So visit your authorized Yamaha dealer to get all the facts.
Page 96
Yamaha Limited Warranty expires. A special note: If visiting your dealer isn’t convenient, contact Yamaha with your Primary ID number (your frame number). We’ll be happy to help you get the Y.E.S. coverage you need.
Page 97
INDEX Engine idling speed, checking....7-17 Noise regulation........10-4 Engine oil and oil filter element ....7-12 Air filter element and check hose, Engine, starting a warm ......6-2 cleaning ..........7-15 Parking............6-4 Engine stop switch ........4-3 Part locations ..........3-1 Battery .............7-31 Front fork, checking.........
Page 98
INDEX Turn signal light bulb, replacing ....7-36 Turn signal switch ........4-3 Valve clearance ........7-18 Vehicle Emission Control Information label ............10-2 Vehicle identification number ....10-1 Warranty, extended........10-9 Warranty, limited ........10-7 Wheel bearings, checking......7-31 Wheel (front) ..........7-37 Wheel (rear) ..........7-39 Wheels .............7-20...
Page 99
Yamalube – Take care of your Yamaha with legendary Yamalube oils, lubricants, and care products. They’re formulated and approved by the toughest judges we know: the Yamaha engineering teams that know your Yamaha from the inside out.
Page 100
YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2011.03–0.1×1 !