Yamaha TW200 Manuale utente

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THIS MANUAL

WAS PRINTED IN

1987!!! THINGS

HAVE

CHANGED!!!

REFER TO

SUPPLEMENT

BEFORE DOING

ANY WORK!!!!

TW200/200E (T-A)

87-90

SERVICE

MANUAL

Yamaha

Motor

Corporation,

U.S.A.

1st

Edition,

January

1987

All

rights

reserved.

Any

reprinting

unauthorized

use

without

the

written

permission

Yamaha

Motor

Corporation,

U.S.A.

expressly

prohibited.

Printed

U.S.A.

PIN:

LIT-11616-06-26

NOTICE

This manual was written by the Yamaha

Motor

Company primarily

for

use by Yamaha dealers and

their qualified mechanics. It

not

possible

put

entire mechanic's education into

one·

manual,

is assumed that persons using this book

perform maintenance and repairs on Yamaha motor-

cycles have abasic understanding

the mechanical concepts and procedures inherent in motorcycle

repair technology.

Without

such knowledge, attempted repairs or service

this model may render

unfit

use

and/

or unsafe.

Yamaha

Motor

Company, Ltd.

continually striving

improve

all

models manufactured by Yamaha.

Modifications and significant changes in specifications or procedures will be forwarded

all

Authorized

Yamaha dealers and will, where applicable, appear in future editions

this manual.

TECHNICAL

PUBLICATIONS

SERVICE

DIVISION

MOTORCYCLE

OPERATIONS

YAMAHA

MOTO.R CO., LTD.

HOW

TO USE THIS

MANUAL

PARTICULARLY

IMPORTANT

INFORMATION

This material

distinguished by the following notation.

NOTE: A

NOTE

provides key information

make procedures easier or clearer.

:~i~i~j~I

••

ilili:·:'::

ACAUTION indicates special procedures that must be followed

avoid damage

::::::::;:::::::::;:;:::::::::::::::::::::::::::::;:;:::::::::;:::::::::;:::::;:;:;:

::::::::~::'

the motorcycle.

WARNING:

AWARNING indicates special procedures that must be followed

avoid injury

amotorcycle operator or person inspecting or repairing the motorcycle.

MANUAL

FORMAT

All

the procedures in this manual are organized in asequential, step-by-step format. The informa-

tion has been compiled

provide the mechanic

with

easy

read, handy reference that contains

comprehensive explanations

all

disassembly, repair, assembly, and inspection operations.

In this revised format, the condition

afaulty component will precede

arrow symbol and the course

action required will follow the symbol, e.g.,

•Bearings

Pitting/Damage

Replace.

EXPLODED

DIAGRAM

Each

chapter provides exploded diagrams b,efore each disassembly section

for

ease

in identifying cor-

rect disassembly and assembly procedures.

I,~~~

~llsPEcl

~g~

....-E_N_G

~_'_.--'

COOLI

II-CA-RB"---I

'-1

(j) @

ICHASI~

ELECI

i~:t'~1

?I®

I·{l>

ILLUSTRATED

SYMBOLS

(Refer

the

illustration)

IlIus~rated

symbols

are

designed

thumb tabs

indicate the chapter's numberand

content.

General information

®Specifications

@Periodic inspection and adjustment

@Engine

@Cooling system

@Carburetion

(j)

Chassis

@Electrical

®Troubleshooting

Illustrated symbols @

®are used

identify

the

specifications appearing in the text.

®Filling fluid

@Lubricant

@Special tool

@Tightening

@Wear limit, clearance

®Engine speed

@O,V,A

@@@

111

mme

@@@

~E-

~L=Sn

~E.....-

Illustrated symbols @

@in the exploded dia-

gram indicate grade

lubricant and location

lubrication point.

Apply

engine oil

Apply

gear oil

Apply

molybdenum disulfide oil

Apply

wheel bearing grease

Apply

lightweight lithium-soap

base

grease

Apply

molybdenum disulfide grease

Apply

locking agent (LOCTITE®)

INDEX

GENERAL

INFORMATION

SPECIFICATIONS

PERIODIC INSPECTION

AND

ADJUSTMENT

ENGINE

OVERHAUL

CARBURETION

CHASSIS

ELECTRICAL

TROUBLESHOOTING

GEN

INFO

SPEC

P.I

INSP

ADJ

-----~

ENG

•

CARB

c!cr"G

------

CHAS

J.:

eE5l

ELEC

•

""'-TR-B-L

SHTG

~e~

CONTENTS

CHAPTER 1

GENERAL

INFORMATION

MOTORCYCLE IDENTIFICATION

1-1

VEHICLE IDENTIFICATION

NUMBER

1-1

ENGINE SERIAL

NUMBER

1-1

IMPO'RTANT

INFORMATION

1-2

PREPARATION

FOR

REMOVAL

AND

DiSASSEMBLy

1-2

ALL

REPLACEMENT

PARTS

1-3

GASKETS,

OIL

SEALS,

AND

O-RINGS 1-3

LOCK

WASHERS/PLATES

AND

COTTER PINS 1-3

BEARINGS

AND

OIL

SEALS

1-3

CIRCLIPS 1-4

SPECIAL TOOLS 1-4

FOR

TUNE-UP 1-4

FOR

ENGINE SERVICE '1-5

FOR

CHASSIS

SERVICE

1-7

FOR

ELECTRICAL COMPONENTS 1-8

CHAPTER 2

SPECIFICATIONS

GENERAL SPECiFiCATIONS

2-1

MAINTENANCE

SPECIFICATIONS 2-4

ENGINE 2-4

CHASSiS

2-11

ELECTRICAL 2-14

GENERAL TORQUE SPECIFICATIONS 2-16

DEFINITION OF UNITS

2-16

LUBRICATION

POINTS

AND

TYPE

LUBRICANTS

2-17

ENGINE

2-17

CHASSIS

2-18

LUBRICATION

DIAGRAMS

2-19

CABLE ROUTING

2-21

CHAPTER 3

PERIODIC INSPECTION

AND

ADJUSTMENT

INTRODUCTION

3-1

•

ENG

GEN

INFO

INSP

ADJ

SPEC

ELEC

CARB

ELECTRICAL 3-29

BATTERY INSPECTION 3-29

FUSE INSPECTION

3-31

HEADLIGHT BEAM

ADJUSTMENT

3-32

HEADLIGHT BULB REPLACEMENT 3-32

CHASSiS

3-19

FRONT BRAKE ADJUSTMENT 3-19

REAR

BRAKE ADJUSTMENT '3-20

BRAKE SHOE INSPECTION

3-21

BRAKE LIGHT SWITCH

ADJUSTMENT

3-21

DRIVE CHAIN SLACK

ADJUSTMENT

3-21

DRIVE CHAIN LUBRiCATION 3-22

STEERING HEAD ADJUSTMENT 3-23

FRONT FORK OIL REPLACEMENT 3-24

TIRE INSPECTION 3-26

WHEEL INSPECTION 3-27

SPOKE INSPECTION AND TIGHTENING 3-27

CABLE INSPECTION AND LUBRiCATION 3-28

ENGINE 3-3

VALVE CLEARANCE

ADJUSTMENT

3-3

CAM CHAIN ADJUSTMENT 3-5

IDLE

SPEED

ADJUSTMENT 3-6

THROTTLE CABLE

FREE

PLAY

ADJUSTMENT

3-7

SPARK PLUG INSPECTION '3-8

IGNITION TIMING CHECK 3-9

COMPRESSION PRESSURE MEASUREMENT 3-10

ENGINE OIL LEVEL INSPECTION

3-11

ENGINE OIL REPLACEMENT "3-12

CLUTCH

ADJUSTMENT

3-15

AIR FILTER CLEANING 3-17

CARBURETOR JOINT INSPECTION

3-18

FUEL LINE INSPECTION 3-19

CRANKCASE VENTILATION HOSE INSPECTION 3-19

EXHAUST SYSTEM INSPECTION 3-19

PERIODIC

MAINTENANCE/LUBRICATION

INTERVALS

3-1

•

TRBL

~.l

SHTG

~e~

CHAPTER 4

ENGINE

OVERHAUL

ENGINE

REMOVAL

4-1

FUEL

TANK

4-1

EXHAUST

PIPE

AND

ENGINE GUARD

4-1

CRANKCASE

COVER

(LEFT) 4-2

DRIVE SPROCKET 4-2

CARBURETOR 4-3

WIRING AND CABLES 4-3

ENGINE REMOVAL 4-4

DISASSEMBLY

4-5

.CYLINDER HEAD 4-5

CYLINDER 4-6

PiSTON 4-7

CLUTCH 4-8

STARTER MOTOR 4-9

OIL PUMP 4-10

PRIMARY DRIVE GEAR

AND

BALANCER

GE,A,R

4-10

KICK AXLE

4-11

SHIFT SHAFT 4-12

CDI MAGNETO 4-13

CAM CHAIN

AND

CAM

CHAIN GUIDE (INTAKE) 4-14

CRANKCASE (LEFT) 4-14

SHIFTER

AND

TRANSMiSSiON

:4-15

BALANCER

AND

CRANKSHAFT 4-16

VALVE,

ROCKER

ARM

AND

CAMSHAFT

4-16

INSPECTION

AND

REPAIR

4-19

CYLINDER HEAD 4-19

VALVE

AND

VALVE GUIDE

4-20.

VALVE SEAT 4-22

VALVE SPRING 4-25

CAMSHAFT

'4-26

ROCKER ARM

AND

ROCKER

ARM

SHAFT 4-26

CAM

CHAIN

AND

CAM SPROCKET 4-27

CAM

CHAIN GUIDE 4-28

CYLINDER

AND

PISTON 0

•••••••••••••••••••••••••••••••••

4-28

PISTON

RING

•••••

4-30

PISTON

4-31

CLUTCH

4-31

OIL PUMP 4-32

PRIMARY DRIVE 4-33

TRANSMISSION

AND

SHIFTER 4-33

KICK STARTER 4-34

CRANKSHAFT 4-35

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