Vehicle Segment:
Recreational Off-Road/ATV (early precursor). Positioned as a unique, high-traction utility vehicle with oversized tires.
Target Audience:
Enthusiasts seeking off-road capability, utility, and a distinctive riding experience. DIY mechanics needing in-depth repair information.
Competitors:
Early ATVs from Honda (e.g., ATC series), Kawasaki (e.g., Tecate), Suzuki (e.g., QuadSport). However, the Big Wheel's unique tire design offered a distinct advantage in soft terrain.
Tire Design:
Its defining feature: oversized, low-pressure balloon tires for exceptional flotation and traction on sand, mud, and snow.
Engine Type:
Reliable and torquey air-cooled 200cc 4-stroke engine, known for its durability.
Transmission:
Simple and reliable 5-speed transmission with an automatic centrifugal clutch.
Engine:
Complete engine disassembly, assembly, inspection, repair, tuning, and troubleshooting of the 200cc 4-stroke engine.
Fuel System:
Carburetor (model and specifications), fuel lines, fuel pump (if applicable), and fuel tank maintenance and repair.
Ignition System:
CDI ignition system, spark plug specifications, ignition timing, coil testing, and troubleshooting.
Drivetrain:
Chain drive system, sprockets, maintenance, adjustment, and replacement procedures. Details on the automatic clutch system.
Suspension:
Front fork assembly (oil type, level, seals), rear shock absorber, linkage, and adjustments for optimum performance.
Brakes:
Front and rear drum brake systems, brake shoe inspection, adjustment, replacement, and cable maintenance.
Electrical System:
Lighting system (headlight, taillight, indicators), battery, wiring diagrams, component testing (e.g., stator, regulator/rectifier).
Cooling System:
Air-cooled engine operation and cooling fin maintenance. (Note: BW200 is air-cooled, so detailed liquid cooling procedures are not applicable).
Chassis And Frame:
Frame inspection, steering system components (bearings, seals), and general chassis maintenance.
Wheels And Tires:
Tire specifications, inflation pressures, wheel bearing maintenance, and tire replacement.
Maintenance:
Routine service checks, lubrication points, filter replacement, spark plug maintenance, and brake adjustments.
Troubleshooting:
Diagnostic guides for common running issues, electrical problems, and performance deficiencies, often with symptom-based tables.
Repair:
Step-by-step instructions for component disassembly, cleaning, inspection, repair, and reassembly for all major systems.
Rebuilds:
Detailed procedures for complete engine rebuilds, including piston/cylinder, crankshaft, and valve train overhauls.
Adjustments:
Specific procedures for adjusting carburetor idle speed, throttle cable, brake levers/pedals, and chain tension.
Diagnostics:
Testing methods and specifications for electrical components, ignition system, and engine performance parameters.
Depth:
Comprehensive factory-level detail suitable for professional mechanics and experienced DIY enthusiasts. Includes torque specifications, clearances, and tolerances.
Special Tools:
Identification of specific tools required for certain procedures, though often standard metric tools are sufficient.
File Type:
PDF (Portable Document Format)
Searchability:
Likely text-searchable, allowing quick access to specific topics.
Printability:
Designed to be printable, allowing users to print specific sections or the entire manual.
Binding Physical:
Not applicable for PDF download, but a printed version would typically be comb-bound or perfect-bound for ease of use.
Paper Physical:
Not applicable for PDF download, but a factory manual would traditionally be printed on durable paper stock.
Engine Type:
Air-cooled, 4-stroke, SOHC, 2-valve
Displacement:
195cc (approximate, often rounded to 200cc)
Bore X Stroke:
Specific bore and stroke dimensions would be found in the manual, crucial for engine rebuilds. Typical for this era might be around 64mm x 58mm.
Compression Ratio:
Details will be in the manual, essential for engine diagnostics and performance tuning.
Carburetor:
Mikuni VM series (specific model and jetting details in manual).
Horsepower:
Estimated around 15-18 HP (typical for this class and era, exact figures in manual).
Torque:
Torque figures not typically advertised but engine characteristics favor low-end grunt for off-road use.
Fuel Type:
Unleaded gasoline (Octane rating specified in manual).
Fuel Tank Capacity:
Approximately 2.5 - 3.0 gallons (specific capacity detailed in manual).
Transmission Type:
5-speed constant mesh manual with automatic centrifugal clutch
Clutch Type:
Automatic centrifugal clutch
Gear Ratios:
Specific gear ratios for each of the 5 speeds and the final drive ratio are provided in the manual.
Drive Type:
Chain drive to rear wheel.
Engine Oil Type:
Yamaha recommends specific grades, likely SAE 10W-30 or 10W-40 motorcycle oil meeting API SG or higher. Manual will confirm exact specification and API service classification.
Transmission Oil Capacity:
Engine oil serves as transmission oil; capacity will be specified for oil changes and total engine fill.
Overall Length:
Specific dimensions would be detailed in the manual. Likely around 75-80 inches.
Overall Width:
Determined by tire width, very wide for its class. Front tire approx. 25x12-9, Rear tire approx. 25x12-9.
Overall Height:
Specific dimensions would be detailed in the manual. Likely around 45-50 inches.
Dry Weight:
Around 300-330 lbs (specific figures in manual).
Payload Capacity:
Not formally specified, but designed for utility; check manual for any load recommendations.
Oil Change:
Typically every 1000 km or 6 months, whichever comes first. Check manual for precise intervals based on usage.
Air Filter:
Inspection every 1000 km, cleaning/replacement as needed based on conditions. Manual will provide specific procedures.
Spark Plug:
Check and clean at 1000 km, replace at recommended intervals (e.g., 5000 km). Manual lists correct spark plug type and gap.
Chain Tension:
Check and adjust every 500 km or as needed. Manual details correct slack.
Engine Oil Grade:
SAE 10W-30 or 10W-40 motorcycle oil (API SG or higher recommended). Manual specifies exact grade and API classification.
Fork Oil Type:
Specific ATF fluid or dedicated fork oil. Manual will specify viscosity (e.g., SAE 10W) and quantity per fork leg.
Carburetor Clogging:
Can occur with infrequent use or poor fuel quality. Manual provides cleaning and rebuilding steps.
Rear Axle Seal Leaks:
Potential for seal wear over time. Manual details seal replacement procedures.
Suspension Seal Leaks:
Front fork seals can degrade. Manual covers fork seal replacement.
