Yamaha TW 200 TRAILWAY 1987-2012 Service Repair Workshop Manual 1988-2011
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🏷️ Basic Information Identification Make: Yamaha Model: TW200 TRAILWAY Model Nickname: Trailway Vehicle Type: Dual-sport Motorcycle Codes Vin Code: Refer to vehicle's VIN plate for specific chassis and engine codes 👋 Introduction Market Position Market Segment: Entry-level to mid-range dual-sport motorcycle, known for its unique fat tires and versatility on various terrains. Target Audience: Beginner riders, casual trail riders, commuters, and owners seeking a reliable and easy-to-maintain motorcycle. Competitive Analysis Key Competitors: Honda CRF250L, Kawasaki KLX230, Suzuki DR200S. Unique Selling Proposition: The TW200's distinctive ultra-wide tires provide exceptional traction and stability, particularly in soft terrain like sand or mud, making it a niche but highly capable option. Key Features Feature 1: Ultra-wide, low-pressure tires for superior off-road grip and comfort. Feature 2: Simple, air-cooled engine designed for reliability and ease of maintenance. Feature 3: Lightweight and maneuverable, ideal for navigating trails and urban environments. Feature 4: Durable construction and proven Yamaha engineering. 📋 Manual Details Coverage Areas Covered Model Years: 1987-2012 Specific Model Years Highlighted: 1988-1992, 1993-2012 (detailed coverage) Page Count Estimated Page Count: Information not explicitly stated, but described as 'detailed' and potentially up to 5GB in size, suggesting a comprehensive document. Manual Type Manual Type: Service Repair Workshop Manual Related Manuals Mentioned: Illustrated Parts Manual, Owner's Manual, User Manual, Operating Manual, Instruction Manual, Shop Manual, Parts List, Maintenance Manual, Technical Workshop Manual, Repair Guide Language Language: English Format Delivery Format: Digital Download (PDF, ZIP, RAR, EXE) Compatibility: Windows, Linux, Mac OS (e.g., Windows 97, 2000, Me, XP, Vista, 7, 10) Digital Rights: Printable and savable to disk without restrictions. 📖 Manual Coverage Systems Covered Engine: Engine disassembly, assembly, tuning, diagnosis, lubrication, cooling system, fuel system, ignition system, exhaust system, emissions control. Transmission: Clutch, gearbox, final drive (chain and sprockets). Chassis: Frame, suspension (front forks, rear shock absorber), steering system, wheels, tires, brakes (front and rear), swingarm. Electrical: Battery, charging system (generator/stator, regulator/rectifier), lighting system (headlight, taillight, turn signals), ignition system, starter motor, wiring diagrams, fuse box, instrument cluster. Bodywork And Fittings: Fuel tank, seat, fenders, side covers, handlebars, controls, footpegs, kickstand, luggage racks (if applicable). Procedures Included Maintenance: Routine checks, lubrication, filter changes, valve clearance adjustment, chain adjustment, brake pad replacement, spark plug service, air filter cleaning/replacement. Repair And Rebuild: Complete engine rebuild, carburetor overhaul, suspension component replacement, brake system repair, electrical component troubleshooting and replacement, wheel bearing service. Troubleshooting: Step-by-step diagnostic procedures for common and uncommon problems, fault finding guides, electrical troubleshooting charts. Technical Specifications: Torque specifications for all fasteners, engine specifications, dimensions, weights, electrical component data, fluid capacities and types. Technical Depth Depth Of Coverage: Comprehensive; covers everything from basic maintenance to complete engine and chassis rebuilds, suitable for DIY enthusiasts and professional mechanics. Illustrations: Illustrated with clear step-by-step instructions, zoomable illustrations, exploded views, and detailed component breakdowns. 📊 Manual Specifications File Format Primary File Format: PDF Compression Formats: ZIP, RAR (requires extraction software like WinZip or WinRAR) Print Quality Print Capability: Printable for hard copy reference. Searchability: Likely text-searchable if created from digital original, aiding in quick information retrieval. Binding Type Binding Type Digital: N/A (Digital file) Paper Type Paper Type Digital: N/A (Digital file) ⚙️ Engine Specifications Primary Engine Engine Type: Air-cooled, four-stroke, SOHC, two-valve, single-cylinder Displacement: 196 cc Bore X Stroke: 67.0 mm x 55.7 mm Compression Ratio: 9.5:1 Fuel Delivery: Carburetor (e.g., Mikuni VM26) Ignition: CDI (Capacitor Discharge Ignition) Starting System: Kick start (later models may have electric start as an option or addition) Performance Horsepower: Approximately 15-17 hp (exact figures may vary by year and specific model tuning) Torque: Approximately 10-12 lb-ft (exact figures may vary by year) Fuel System Carburetor Size: Typically 26mm (Mikuni VM26) Fuel Tank Capacity: Approximately 1.8 US gallons (7.0 liters) 🔧 Transmission Standard Transmission Type: 5-speed manual transmission Clutch Type: Wet, multiple-disc, manual clutch Optional Final Drive: Chain drive Features Gear Ratios: Specific gear ratios will be detailed within the manual, crucial for understanding acceleration and top-speed performance characteristics. 📐 Dimensions Exterior Overall Length: Approx. 81.5 in (2070 mm) Overall Width: Approx. 33.7 in (855 mm) Overall Height: Approx. 42.1 in (1070 mm) Seat Height: Approx. 31.9 in (810 mm) Ground Clearance: Approx. 6.5 in (165 mm) Weights Dry Weight: Approx. 258 lbs (117 kg) Wet Weight: Approx. 275 lbs (125 kg) (with fluids) Front Tire Size: 130/80-18 (or 180/80-18 for some specific variants/upgrades) Rear Tire Size: 180/80-14 (or 180/80-14 for some specific variants/upgrades) Wheelbase: Approx. 51.6 in (1310 mm) 🛡️ Safety Features Ratings Safety Ratings: Motorcycle safety is primarily determined by rider skill and adherence to traffic laws. The TW200's design prioritizes stability and predictable handling. Active Features Active Safety Features: Disc brakes (front), Drum brake (rear), Wide tires for improved stability, Responsive throttle and clutch control. Passive Features Passive Safety Features: Sturdy frame, appropriate suspension damping, protective bodywork (fenders, shrouds). 💡 Technology Features Infotainment...
Refer to vehicle's VIN plate for specific chassis and engine codes
👋 Introduction
Market Position
Market Segment:
Entry-level to mid-range dual-sport motorcycle, known for its unique fat tires and versatility on various terrains.
Target Audience:
Beginner riders, casual trail riders, commuters, and owners seeking a reliable and easy-to-maintain motorcycle.
Competitive Analysis
Key Competitors:
Honda CRF250L, Kawasaki KLX230, Suzuki DR200S.
Unique Selling Proposition:
The TW200's distinctive ultra-wide tires provide exceptional traction and stability, particularly in soft terrain like sand or mud, making it a niche but highly capable option.
Key Features
Feature 1:
Ultra-wide, low-pressure tires for superior off-road grip and comfort.
Feature 2:
Simple, air-cooled engine designed for reliability and ease of maintenance.
Feature 3:
Lightweight and maneuverable, ideal for navigating trails and urban environments.
Feature 4:
Durable construction and proven Yamaha engineering.
📋 Manual Details
Coverage Areas
Covered Model Years:
1987-2012
Specific Model Years Highlighted:
1988-1992, 1993-2012 (detailed coverage)
Page Count
Estimated Page Count:
Information not explicitly stated, but described as 'detailed' and potentially up to 5GB in size, suggesting a comprehensive document.
Manual Type
Manual Type:
Service Repair Workshop Manual
Related Manuals Mentioned:
Illustrated Parts Manual, Owner's Manual, User Manual, Operating Manual, Instruction Manual, Shop Manual, Parts List, Maintenance Manual, Technical Workshop Manual, Repair Guide
Language
Language:
English
Format
Delivery Format:
Digital Download (PDF, ZIP, RAR, EXE)
Compatibility:
Windows, Linux, Mac OS (e.g., Windows 97, 2000, Me, XP, Vista, 7, 10)
Digital Rights:
Printable and savable to disk without restrictions.
Routine checks, lubrication, filter changes, valve clearance adjustment, chain adjustment, brake pad replacement, spark plug service, air filter cleaning/replacement.
Repair And Rebuild:
Complete engine rebuild, carburetor overhaul, suspension component replacement, brake system repair, electrical component troubleshooting and replacement, wheel bearing service.
Troubleshooting:
Step-by-step diagnostic procedures for common and uncommon problems, fault finding guides, electrical troubleshooting charts.
Technical Specifications:
Torque specifications for all fasteners, engine specifications, dimensions, weights, electrical component data, fluid capacities and types.
Technical Depth
Depth Of Coverage:
Comprehensive; covers everything from basic maintenance to complete engine and chassis rebuilds, suitable for DIY enthusiasts and professional mechanics.
Illustrations:
Illustrated with clear step-by-step instructions, zoomable illustrations, exploded views, and detailed component breakdowns.
📊 Manual Specifications
File Format
Primary File Format:
PDF
Compression Formats:
ZIP, RAR (requires extraction software like WinZip or WinRAR)
Print Quality
Print Capability:
Printable for hard copy reference.
Searchability:
Likely text-searchable if created from digital original, aiding in quick information retrieval.
Kick start (later models may have electric start as an option or addition)
Performance
Horsepower:
Approximately 15-17 hp (exact figures may vary by year and specific model tuning)
Torque:
Approximately 10-12 lb-ft (exact figures may vary by year)
Fuel System
Carburetor Size:
Typically 26mm (Mikuni VM26)
Fuel Tank Capacity:
Approximately 1.8 US gallons (7.0 liters)
🔧 Transmission
Standard
Transmission Type:
5-speed manual transmission
Clutch Type:
Wet, multiple-disc, manual clutch
Optional
Final Drive:
Chain drive
Features
Gear Ratios:
Specific gear ratios will be detailed within the manual, crucial for understanding acceleration and top-speed performance characteristics.
📐 Dimensions
Exterior
Overall Length:
Approx. 81.5 in (2070 mm)
Overall Width:
Approx. 33.7 in (855 mm)
Overall Height:
Approx. 42.1 in (1070 mm)
Seat Height:
Approx. 31.9 in (810 mm)
Ground Clearance:
Approx. 6.5 in (165 mm)
Weights
Dry Weight:
Approx. 258 lbs (117 kg)
Wet Weight:
Approx. 275 lbs (125 kg) (with fluids)
Front Tire Size:
130/80-18 (or 180/80-18 for some specific variants/upgrades)
Rear Tire Size:
180/80-14 (or 180/80-14 for some specific variants/upgrades)
Wheelbase:
Approx. 51.6 in (1310 mm)
🛡️ Safety Features
Ratings
Safety Ratings:
Motorcycle safety is primarily determined by rider skill and adherence to traffic laws. The TW200's design prioritizes stability and predictable handling.
Active Features
Active Safety Features:
Disc brakes (front), Drum brake (rear), Wide tires for improved stability, Responsive throttle and clutch control.
Basic analog instrument cluster with speedometer, odometer, and indicator lights. No advanced infotainment systems.
Driver Assistance
Driver Assistance Features:
N/A (Focus is on mechanical simplicity and rider control)
🔧 Maintenance
Service Intervals
Oil Change Interval:
Recommended every 3,000 miles (4,800 km) or 6 months, whichever comes first. Refer to the manual for precise interval based on riding conditions.
Valve Clearance Check Interval:
Typically every 6,000 miles (9,600 km) or annually. Consult the manual for precise specifications and adjustment procedures.
Air Filter Cleaning Interval:
Inspect every 1,000 miles (1,600 km) and clean or replace as needed, more frequently in dusty conditions.
Chain Lubrication And Adjustment:
Lubricate the chain every 500 miles (800 km) and check for proper tension and wear at the same intervals. Adjust as per manual specifications.
Fluid Specifications
Engine Oil Type:
Yamaha recommends Yamalube 4 (10W-40) or equivalent API service SG type or higher motorcycle oil. Check manual for specific viscosity recommendations based on temperature.
Engine Oil Capacity:
Approx. 1.4 US quarts (1.3 liters) with oil filter change. Refer to manual for exact capacity.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid for the front disc brake. Ensure proper fluid level is maintained.
Coolant Type:
N/A (Air-cooled engine)
Known Issues
Common Wear Items:
Tires (due to unique design and use), brake pads, chain and sprockets, spark plug, air filter, clutch plates (with high mileage).
Carburetor Tuning:
Can require occasional adjustments for optimal performance, especially if used in varying altitudes or after extended storage.
Kickstarter Engagement:
Ensure the kickstarter is fully engaged and returned to its resting position to prevent potential issues.
📚 Vehicle History
Brand Heritage
Yamaha Heritage:
Yamaha Motor Corporation, established in 1955, has a long and illustrious history in motorcycle manufacturing, known for innovation, performance, and reliability across various motorcycle segments.
Model Evolution
Tw200 Evolution:
The TW200 was introduced in the mid-1980s and has remained largely unchanged in its core design due to its effective and unique formula. Minor updates have occurred over the years, including carburetor adjustments, emissions controls, and cosmetic changes, but the fundamental character has been preserved.
Key Design Philosophy:
The 'Trailway' concept emphasizes ease of use, off-road capability in soft conditions, and durability, making it a favored choice for recreational riding and specific utility tasks.
Production
Production Start Year:
1987
Production End Year Covered By Manual:
2012
Manufacturing Locations:
Primarily manufactured in Japan.
🏆 Awards & Recognition
Recognitions
Industry Recognitions:
While specific awards are not widely publicized, the TW200 is consistently praised for its unique capability in soft terrain and its enduring appeal as a reliable, go-anywhere motorcycle.
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