1985-1989 Yamaha BW200 Big Wheel Service & Repair Manual

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NOTICE This manual was written by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to put an entire mechanic's education into one manual, so it is assumed that persons using this book to perform maintenance and repairs on Yamaha motorcycles have a basic understanding of the mechanical concepts and procedures inherent in motorcycle repair technology. Without such knowledge, attempted repairs or service to this model may render it unfit to use and/ or unsafe. Yamaha Motor Company, Ltd. is continually striving to improve all models manufactured by Yamaha. Modifications are significant changes in specifications or procedures will be for- warded to all Authorized Yamaha dealers and will, where applicable, appear in future edi- tions of this manual. OVERSEAS SERVICE OVERSEAS OPERATIONS YAMAHA MOTOR CO., LTD. HOW TO USE THIS MANUAL PARTICULARLY IMPORTANT INFORMATION This material is distinguished by the following notation. NOTE: WARNING: A NOTE provides key information to make procedures easier or clearer. A CAUTION indicates special procedures that must be followed to avoid damage to the motorcycle. A WARNING indicates special procedures that must be followed to avoid injury to a motorcycle operator or person inspecting or repairing the motorcycle. MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been compiled to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations. In this revised format, the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol, e.g., • Bearings; Pitting/ Damage-. Replace. EXPLODED DIAGRAM Each chapter provides exploded diagrams before each disassembly section for ·ease in identifying correct disassembly and assembly procedures.

CD ® ~~~~~~~ 1':8~1 §ll ® @ IENGI'·I lcooLI ~I ® ® ~~fl EHASibel (J) ® IELECI §I ~p~·"l ® ~ @ ~ QD ~ @ ~ @ [8] ([1) 11] @ 1 (j]) 1 @ 1 m m 9 @ @ ® ~~ ~~ ~ ® l a SYMBOLS (Refer to the illustration) Symbols CD to@ are designed as thumb tabs to indicate the chapter's number and content. CD General information @ Periodic inspection and adjustment @Engine @ Cooling system @ Carburetion @Chassis Q) Electrical @ Appendices Symbols @ to ® indicate specific data as the following items: ® Filling fluid ® Lubricant @ Tightening @ Wear limit, clearance @ Engine speed @0, V,A Symbols® to@ in the exploded diagram indicate grade of lubricant and location of lubrication point. ® Apply engine oil ® Apply gear oil @ Apply molybdenum disulfide oil ® Apply w~eel bearing grease @l Apply lightweight lithium soap base grease ® Apply molybdenum disulfide grease @ Apply locking agent (LOCTITE® l

INDEX GENERAL INFORMATION PERIODIC INSPECTIONS AND ADJUSTMENTS ENGINE OVERHAUL CARBURETION '- ENG

-----------------------~~~~~~~ CHAPTER 1. GENERAL INFORMATION MOTORCYCLE IDENTIFICATION ................................. 1-1 VEHICLE IDENTIFICATION NUMBER ............................. 1-1 ENGINE SERIAL NUMBER ......................................... 1-1 IMPORTANT INFORMATION .................................... 1-2 ALL REPLACEMENT PARTS .................................... 1-2 GASKETS, OIL SEALS, AND 0-RINGS ............................ 1-2 LOCK WASHER/PLATES AND COTTER PINS .................... 1-2 BEARINGS AND OIL SEALS .................................... 1-3 CIRCLIPS ...................................................... 1-3 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 FOR TUNE-UP .................................................. 1-4 FOR ENGINE SERVICE ....................................... 1-4 FOR CHASSIS SERVICE ...................................... 1-6 FOR ELECTRICAL COMPONENTS ............................. 1-7

I GENI ~I . INFO . @ . MOTORCYCLE IDENTIFICATION 1-1 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER The vehicle identification number CD is on the left side of the steering head pipe. Starting Serial Number: BW200N ........ JYA54GOO*FA000101 ENGINE SERIAL NUMBER The engine serial number CD is stamped into the elevated part of the right rear section of the engine. Starting Serial Number: BW200N ................. 54G-000101 NOTE: -------------------------- The first three digits of these numbers are for model identifications; the remaining digits are the unit production number. NOTE: -------------------------- Designs and specifications are subject to change without notice.

- --------------------~~-~IGNEFNol IMPORTANT INFORMATION . J'~ . . IMPORTANT INFORMATION ALL REPLACEMENT PARTS 1. Use only genuine Yamaha parts for all replacements. Use oil and/ or grease recom- mended by Yamaha for assembly and adjustment. Other brands may be similar in function and appearance, but inferior· in quality. GASKETS, OIL SEALS, AND 0-RINGS 1. All gaskets, seals, and 0-rings should be replaced when an engine is overhauled. All gasket surfaces, oil seal lips and 0-rings must be cleaned. 2. Properly oil all mating parts and bearings dur- ing reassembly. Apply grease to the oil seal lips. LOCK WASHERS/PLATES AND COTTER PINS 1. All lock washers/ Plates CD and cotter pins must be replaced when they are removed. Lock tab(s) should be bent along the bolt or nut flat(s) after the bolt or nut has been properly tightened. 1-2

~~~~~~~-I_M_P_O_R_T_A_N_T_I_N_FO_R_M __ A_T_IO_N ______________ ___ 1-3 BEARINGS AND OIL SEALS 1. Install the bearing(s) and oil seal(s) with their manufacturer's marks or numbers facing outward. (In other words, the stamped let- ters must be on the side exposed to view.) When installing oil seal(s), apply a light coating of light-weight lithium base grease to the seal lip(s). Oil the bearings liberally when installing. CD Oil seal. Do not use compressed air to spin the bearings dry. This causes damage to the bearing surfaces. CD Bearing CIRCLIPS 1. All circlips should be inspected carefully before reassembly. Always replace piston pin clips after one use. Replace distorted circlips. When installing a circlip CD, make sure that the sharp edged corner~ is positioned op- posite to the thrust @ it receives. See the sectional view. @Shaft

--~---------S_P_E_C_IA_L_T_O_O_L_s_l~l~l SPECIAL TOOLS The proper special tools are necessary for com- plete and accurate tune-up and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or improvis- ed techniques. FOR TUNE-UP 1. Timing Light P/N. YU-08037 2. Inductive Tachometer P/N. YU-08036 3. Compression Gauge and Adapter P/N. YU-33223 YU-33223-3 FOR ENGINE SERVICE 1. Clutch Hub Holder P/N. YM-91042 1-4

~~~~~~~~_S_P_E_C_IA_L_T_O_O_L_S ______________________ _ , ....... , ~ lbJ I~ H ][ H] t.~DOO@ ~~ 1-5 2. Valve Guide Remover P/N. YM-4064-A 3. Valve Guide Installer P/N. YM-4065 4. Valve Guide Reamer P/N. YM-4066 5. Valve Seat Cutter P/N. YM-91043 6. Valve Spring Compressor P/N. YM-04019

1985-1989 Yamaha BW200 Big Wheel Service & Repair Manual

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