2017 Yamaha TW200 Owner’s Manual

The 2017 Yamaha TW200 was a unique and versatile dual-sport motorbike that was known for how well it handled off-road and how well it turned. This bike had a unique look with fat tires and a 196cc air-cooled engine with an electric start, making it a good choice for riders of all skill levels. The TW200’s lightweight design, comfortable seat, and low seat height made it easy to ride on rough trails, busy city streets, or difficult terrain. It was also praised for its “go-anywhere” attitude, which cemented its reputation as a popular and capable dual-sport motorcycle.

Operation and important riding points

WARNING: Failure to familiarize yourself with the controls can lead to loss of control, which could cause an accident or injury.

Starting and warming up a cold engine
In order for the ignition circuit cut-off system to enable starting, one of the following conditions must be met:

• The transmission is in the neutral position.
• The transmission is in gear with the clutch lever pulled and the sid-stand up.

1. Turn the fuel cock lever to “ON”.
2. Turn the key to “ON” and make sure that the engine stop switch is set.
3. Shift the transmission into the neutral position. The neutral indicator light should come on. If not, ask a Yamaha dealer to check the electrical circuit.
4. Turn the starter (choke) on and completely close the throttle.
5. Start the engine by pushing the start switch. If the engine fails to start, release the start switch, wait a few seconds, and then try again. Each starting attempt should be as short as possible to preserve the bat-tery. Do not crank the engine for more than 10 seconds on any one attempt.
6. After starting the engine, move the starter (choke) back halfway.
7. When the engine is warm, turn the starter (choke) off.

TIP
The engine is warm when it responds quickly to the throttle with the starter (choke) turned off. To avoid the possibility of excessive exhaust emissions, never leave the starter (choke) on longer than necessary. The time necessary for starter (choke) use depends upon the ambient temperature. Temperatures above 10 °C (50 °F) require about 7 seconds of starter (choke) use and temperatures below 10 °C (50 °F) require about 35 seconds with the starter (choke) turned on, then about 2.5 minutes with the starter (choke) in the halfway position.
NOTICE: For maximum engine life, never accelerate hard when the engine is cold.

Starting a warm engine
Follow the same procedure as for starting a cold engine with the exception that the starter (choke) is not required when the engine is warm.

Shifting

1. Shift pedal
2. Neutral position

Shifting gears lets you control the amount of engine power available for starting off, accelerating, climbing hills, etc. The gear positions are shown in the illustration.
TIP: To shift the transmission into the neutral position, press the shift pedal down repeatedly until it reaches the end of its travel, and then slightly raise it.

NOTICE

• Even with the transmission in the neutral position, do not coast for long periods of time with the engine off, and do not tow the motorcycle for long distances. The transmission is properly lubricated only when the engine is running. Inadequate lubrication may damage the transmission.
• Always use the clutch while changing gears to avoid damaging the engine, transmission, and drive train, which are not designed to withstand the shock of forced shifting.

To start out and accelerate

• Pull the clutch lever to disengage the clutch.
• Shift the transmission into first gear. The neutral indicator light should go out.
• Open the throttle gradually, and at the same time, release the clutch lever slowly.
• At the recommended shift points shown in the following table, close the throttle, and at the same time, quickly pull the clutch lever in.
• Shift the transmission into second gear. (Make sure not to shift the transmission into the neutral position.)
• Open the throttle partway and gradually release the clutch lever.
• Follow the same procedure when shifting to the next higher gear.
  TIP: When shifting gears in normal operating conditions, use the recommended shift points.

To decelerate

1. Apply both the front and the rear brakes to slow the motorcycle.
2. Shift the transmission into first gear when the motorcycle reaches 20 km/h (12 mph). If the engine is about to stall or runs very roughly, pull the clutch lever in and use the brakes to stop the motorcycle.
3. Shift the transmission into the neutral position when the motorcycle is almost completely stopped. The neutral indicator light should come on.

Recommended shift points
The recommended shift points during acceleration and deceleration are shown in the table below.

Engine break-in
There is never a more important period in the life of your engine than the period between 0 and 1600 km (1000 mi). For this reason, you should read the following material carefully. Since the engine is brand new, do not put an excessive load on it for the first 1600 km (1000 mi). The various parts in the engine wear and polish themselves to the correct operating clearances. During this period, prolonged full-throt-tle operation or any condition that might result in engine overheating must be avoided.

1. 0–1000 km (0–600 mi)
   Avoid prolonged operation above 1/3 throttle. 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, immediately have a Yamaha dealer check the vehicle.
2. 1000–1600 km (600–1000 mi)
   Avoid prolonged operation above 1/2 throttle.
3. 1600 km (1000 mi) and beyond
   The vehicle can now be operated normally.

Parking
When parking, stop the engine, remove the key from the main switch, and then turn the fuel cock lever to “OFF”.
WARNING

• Since the engine and exhaust system can become very hot, park in a place where pedestrians or children are not likely to touch them and be burned.
• Do not park on a slope or on soft ground, otherwise, the vehicle may overturn, increasing the risk of a fuel leak and fire.
• Do not park near grass or other flammable materials which might catch fire.

Periodic maintenance and adjustment

Periodic inspection, adjustment, and lubrication will keep your vehicle in the safest and most efficient condition possible. Safety is an obligation of the vehicle owner/operator. The most important points of vehicle inspection, adjustment, and lubrication are explained on the following pages. The intervals given in the periodic maintenance charts should be simply considered as a general guide under normal riding conditions. However, depending on the weather, terrain, geographical location, and individual use, the maintenance intervals may need to be shortened.
WARNING: Failure to properly maintain the vehicle or perform maintenance activities incorrectly may increase your risk of injury or death during service or while using the vehicle. If you are not familiar with vehicle service, have a Yamaha dealer perform service. Turn off the engine when performing maintenance unless otherwise specified.

• A running engine has moving parts that can catch on body parts or clothing and electrical parts that can cause shocks or fires.
• Running the engine while ser-vicing can lead to eye injury, burns, fire, or carbon monoxide poisoning – possibly leading to death.
• Brake discs, calipers, drums, and linings can become very hot during use. To avoid possible burns, let brake components cool before touching them.

Emission controls not only function to ensure cleaner air but are also vital to proper engine operation and maximum performance. In the following periodic maintenance charts, the services related to emissions control are grouped separately. These services require specialized data, knowledge, and equipment. Maintenance, replacement, or repair of the emission control devices and systems may be performed by any repair establishment or individual that is certified (if applicable). Yamaha dealers are trained and equipped to perform these particular services.

Owner’s tool kit
The owner’s tool kit is located behind panel B. The service information included in this manual and the tools provided in the owner’s tool kit are intended to assist you in the performance of preventive maintenance and minor repairs. However, additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly.
TIP: If you do not have the tools or experience required for a particular job, have a Yamaha dealer perform it for you.

• 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 it as required.
  • Replace the oil seals on the inner parts of the master cylinder and caliper cylinder every two years.
  • Replace the brake hoses every four years or if cracked or damaged.

Removing and installing the cowling and panels
The cowling and panels shown need to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time the cowling or a panel needs to be removed and installed.

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 maintenance and lubrication chart. In addition, the condition of the spark plug can reveal the condition of the engine.

To remove the spark plug

1. Remove the spark plug cap.
2. Remove the spark plug as shown, with the spark plug wrench included in the owner’s tool kit.

FAQ’s