![Yamaha TW200N (2000) [6/96] Contents](/img/pdf.png)
Yamaha TW200N (2000) [6/96] Contents
![Yamaha TW200N (2000) [6/96] Contents](/views2/1121455/page6/bg6.png)
CONTENTS
GENERAL INFORMATION
...............................................................................1
MOTORCYCLE IDENTIFICATION ........................................................... 1
VEHICLE IDENTIFICATION NUMBER ................................................1
MODEL CODE .....................................................................................1
SPECIFICATIONS
............................................................................................2
GENERAL SPECIFICATIONS .................................................................2
MAINTENANCE SPECIFICATIONS ........................................................4
ENGINE ................................................................................................4
TIGHTENING TORQUESS .................................................................. 6
CHASSIS .............................................................................................. 7
TIGHTENING TORQUESS .................................................................. 8
ELECTRICAL .......................................................................................9
CABLE ROUTING .................................................................................. 10
PERIODIC CHECKS AND ADJUSTMENTS
.................................................. 18
INTRODUCTION .................................................................................... 18
PERIODIC MAINTENANCE CHART FOR EMISSION
CONTROL SYSTEM .............................................................................. 18
GENERAL MAINTENANCE AND LUBRICATION CHART ....................19
ENGINE ..................................................................................................21
ADJUSTING THE THROTTLE CABLE FREE PLAY .........................21
CLEANING THE SPARK ARRESTER ............................................... 22
CHASSIS ................................................................................................ 23
ADJUSTING THE FRONT BRAKE .................................................... 23
CHECKING THE BRAKE FLUID LEVEL ...........................................24
CHECKING THE BRAKE PADS ........................................................ 25
CHECKING THE BRAKE HOSE ........................................................ 25
BLEEDING THE HYDRAULIC BRAKE SYSTEM .............................. 26
ENGINE
........................................................................................................... 28
CYLINDER HEAD .................................................................................. 28
CHECKING THE TIMING CHAIN TENSIONER ................................ 29
INSTALLING THE TIMING CHAIN TENSIONER .............................. 29
AC MAGNETO ....................................................................................... 30
STATOR COIL ASSEMBLY AND PICKUP COIL ............................... 30
AC MAGNETO ...................................................................................31
CARBURETION
..............................................................................................32
CARBURETOR ......................................................................................32
DISASSEMBLING THE CARBURETOR ............................................35
CHECKING THE CARBURETOR ...................................................... 35
ASSEMBLING THE CARBURETOR ..................................................37
INSTALLING THE CARBURETOR .................................................... 38
MEASURING AND ADJUSTING THE FUEL LEVEL ......................... 39
Содержание
- Foreword 2
- Caution 3
- Important manual information 3
- Notice 3
- Warning 3
- How to use this manual 4
- Carb chas 5
- Chk adj eng 5
- Elec trbl shtg 5
- Gen info 5
- Symbols 5
- Contents 6
- Table of contents 6
- Gen info 8
- General information 8
- Motorcycle identification 8
- General specifications 9
- Specifications 9
- General specifications 10
- Maintenance specifications 11
- Maintenance specifications 12
- Maintenance specifications 13
- Maintenance specifications 14
- Maintenance specifications 15
- Maintenance specifications 16
- Cable routing 17
- Cable routing 18
- Cable routing 19
- Cable routing 20
- Cable routing 21
- Cable routing 22
- Cable routing 23
- Cable routing 24
- Chk adj 25
- Introduction 25
- Introduction periodic maintenance chart for emission control system 25
- Note from 16 000 mi 26 000 km or 30 months repeat the maintenance intervals starting from 4 000 mi 6 000 km or 6 months 25
- Periodic checks and adjustments 25
- Periodic maintenance chart for emission control system 25
- This chapter includes all information necessary to perform recommended checks and abjustments if followed these preventive maintenance procedures will ensure more reliable vehicle operation a longer service life and reduce the need for costly overhaul work this information applies to vehicles already in service as well as to new vehicles that are being prepared for sale all service technicians should be familiar with this entire chapter 25
- Chk adj 26
- General maintenance and lubrication chart 26
- Chk adj 27
- General maintenance and lubrication chart 27
- Note 1 the air filter element needs more frequent service if you are riding in unusually wet or dusty areas 2 hydraulic brake system replace the brake fluid after disassembling the master cylinder or caliper cylinder check the brake fluid level and add fluid as required replace the master cylinder and caliper cylinder oil seals every two years replace the brake hoses every four years or if cracked or damaged 27
- Since these items require special tools data and technical skills have a yamaha dealer perform the ser vice 27
- Adjusting the throttle cable free play 28
- Chk adj 28
- Engine 28
- A remove the screw 1 b remove the tail pipe 2 by pulling it out of the muffler c top the tail pipe lightly then use a wire brush to remove any carbon deposits from the spark arrester 3 portion of the tail pipe d insert the tail pipe into the muffler and align the screw hole e install the screw and tighten it 29
- Adjusting the throttle cable free play cleaning the spark arrester 29
- After adjusting the throttle cable free play start the engine and turn the handlebars to the right and to the left to ensure that this does not cause the engine idling speed to change 29
- Chk adj 29
- Cleaning the spark arrester 1 clean spark arrester 29
- D tighten the locknut 29
- Direction c throttle cable free play is increased 29
- Direction d throttle cable free play is decreased 29
- Do not start the engine when cleaning the exhaust system always let the exhaust system cool before performing this operation 29
- Handlebar side a slide back the rubber cover 3 b loosen the locknut 4 c turn the adjusting nut 5 in direction c or d until the specified throttle cable free play is obtained 29
- Warning 29
- Adjusting the front brake 30
- Caution 30
- Chassis 30
- Chk adj 30
- Warning 30
- Caution 31
- Checking the brake fluid level 31
- Chk adj 31
- Warning 31
- Checking the brake pads checking the brake hose 32
- Chk adj 32
- Bleeding the hydraulic brake system 33
- Chk adj 33
- Warning 33
- After bleeding the hydraulic brake system check the brake operation 34
- Bleed screw 6 nm 0 m kg 4 ft lb 34
- Bleeding the hydraulic brake system 34
- Chk adj 34
- H tighten the bleed screw and then release the brake lever i repeat steps e to h until all of the air bubbles have disappeared from the brake fluid in the plastic hose j tighten the bleed screw to specification 34
- K fill the brake fluid reservoir to the proper level with the recommended brake fluid refer to checking the brake fluid level 34
- Warning 34
- Cylinder head 35
- Engine 35
- Cylinder head 36
- Warning 36
- Ac magneto 37
- Ac magneto 38
- Carburetion 39
- Carburetor 39
- Carburetor 40
- Carburetor 41
- Carburetor 42
- Carburetor 43
- Carburetor 44
- Caution 44
- Carburetor 45
- A remove the carburetor assembly b check the needle valve seat and needle valve c if either is worn replace them as a set d if both are fine adjust the float level by slightly bending the float tang 1 e install the carburetor assembly f measure the fuel level again g repeat steps a to f until the fuel level is within specification 46
- A stand the motorcycle on a level surface b place the motorcycle on a suitable stand to ensure that the motorcycle is standing straight up c install the fuel level gauge 1 onto the fuel drain pipe 2 46
- Adjust fuel level 46
- Carburetor 46
- D loosen the fuel drain screw 3 e hold the fuel level gauge vertically next to the line 4 on the float chamber f measure the fuel level a 46
- Fuel level above the line on the float chamber mating surface 0 1 mm 0 2 0 6 in 46
- Fuel level gauge ym 01312 a 46
- Measuring and adjusting the fuel level 1 measure fuel level a out of specification adjust 46
- Chassis 47
- Front wheel and brake disc 47
- Front wheel and brake disc 48
- Front wheel and brake disc 49
- Warning 49
- A place the motorcycle on a suitable stand so that the wheel is elevated b before measuring the front brake disc deflection turn the handlebars to the left or right to ensure that the front wheel is sta tionary c remove the brake caliper d hold the dial gauge at a right angle against the brake disc surface e measure the deflection 2 3 mm 0 8 0 2 in below the edge of the brake disc 50
- A remove the brake disc b rotate the brake disc by one bolt hole c install the brake disc 50
- Adjust brake disc deflection 50
- Brake disc bolt 13 nm 1 m kg 9 ft lb loctit 50
- Front wheel and brake disc 50
- Max brake disc deflection 0 5 mm 0 06 in 50
- Measure brake disc deflection out of specification correct the brake disc deflection or replace the brake disc 50
- Measure brake disc thickness measure the brake disc thickness at a few different locations out of specification replace 50
- Min brake disc thickness standard 3 mm 0 4 in limit 3 mm 0 2 in 50
- Note tighten the brake disc bolts in stages and in a crisscross pattern 50
- Front wheel and brake disc 51
- Caution 52
- Front wheel and brake disc 52
- Front brake 53
- Caution 54
- Front brake 54
- Front brake 55
- Front brake 56
- Front brake 57
- Front brake 58
- Front brake 59
- Front brake 60
- Warning 60
- Caution 61
- Front brake 61
- Warning 61
- Front brake 62
- Front brake 63
- Front brake 64
- Warning 64
- Front brake 65
- Warning 65
- Caution 66
- Front brake 66
- Warning 66
- Caution 67
- Front brake 67
- Warning 67
- Front brake 68
- Front fork 69
- Steering head 70
- Steering head 71
- Steering head 72
- Electrical 73
- Electrical components 73
- Caution 74
- Switches 74
- Check each switch for damage or wear proper connections and also for continuity between the ter minals refer to checking switch continuity damage wear repair or replace the switch improperly connected properly connect incorrect continuity reading replace the switch 75
- Checking the switches 75
- Checking the switches 76
- Ac magneto 0 engine stop switch a main switch d sidestand switch f cdi unit g ignition coil h spark plug 77
- Circuit diagram 77
- Ignition system 77
- Ignition system 78
- Ignition system 79
- Ignition system 80
- Ignition system 81
- Circuit diagram 82
- Electric starting system 82
- Neutral switch 4 battery 5 main fuse 6 starter relay 7 starter motor 9 start switch 0 engine stop switch a main switch b diode c clutch switch d sidestand switch e neutral relay 82
- Electric starting system 83
- Starting circuit cut off system operation if the engine stop switch is set to and the main switch is set to on both switches are closed the starter motor can only operate if at least one of the following conditions is met 83
- The transmission is in neutral the neutral switch is closed the clutch lever is pulled to the handlebar the clutch switch is closed and the side stand is up the sidestand switch is closed 83
- When the sidestand is up and the clutch lever is pulled to the handlebar 83
- When the transmission is in neutral 83
- Electric starting system 84
- Warning 84
- Electric starting system 85
- Electric starting system 86
- Electric starting system 87
- Battery 88
- Circuit diagram 88
- Front brake light switch 88
- Front turn signal position light 88
- Horn switch 88
- Main fuse 88
- Main switch 88
- Neutral indicator light 88
- Neutral switch 88
- Rear brake light switch 88
- Rear turn signal light 88
- Signaling system 88
- Tail brake light 88
- Turn signal indicator light 88
- Turn signal relay 88
- Turn signal switch 88
- Signaling system 89
- Signaling system 90
- Signaling system 91
- Signaling system 92
- Signaling system 93
- Signaling system 94
- Ac magneto 2 neutral switch 3 rectifier regulator 4 battery 5 main fuse 6 starter relay 7 starter motor 8 right handlebar switch 9 start switch 0 engine stop switch a main switch b diode c clutch switch d sidestand switch e neutral relay f cdi unit g ignition coil h spark plug i meter light j neutral indicator light k turn signal indicator light l high beam indicator light m rear brake light switch n front brake light switch o tail brake light p headlight q rear turn signal light r front turn signal position light s left handlebar switch t horn switch u turn signal switch v dimmer switch w horn x turn signal relay 96
- B black br brown ch chocolate dg dark green g green l blue 96
- B r black red b w brake white br w brown white g w green white g y green yellow l b blue black 96
- Color code 96
- L w blue white l y blue yellow r l red blue r w red white w l white blue w r white red 96
- O orange p pink r red sb sky blue w white y yellow 96
- Tw200en tw200enc wiring diagram 96
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