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Yamaha BW200 Service Manual Repair 1985-1989 BW 200 Big Wheel

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🏷️ Basic Information Identification Make: Yamaha Model: BW200 Nickname: Big Wheel Generation Production Years: 1985-1989 Codes Chassis Code: BW200 👋 Introduction Market Position Segment: Off-road / All-terrain Motorcycle (ATV-like capability)...
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Yamaha BW200 Service Manual Repair 1985-1989 BW 200 Big Wheel
🏷️ Basic Information
Identification
Make:
Yamaha
Model:
BW200
Nickname:
Big Wheel
Generation
Production Years:
1985-1989
Codes
Chassis Code:
BW200
👋 Introduction
Market Position
Segment:
Off-road / All-terrain Motorcycle (ATV-like capability)
Competitive Analysis
Competitors:
Other recreational off-road bikes of the era, early ATVs, utility motorcycles.
Key Features
Distinctive Features:
Extra-wide, low-pressure balloon tires providing excellent traction and flotation on soft terrain (sand, mud, snow), unique styling, robust construction.
Value Proposition
Manual Value:
Provides comprehensive DIY repair and maintenance capabilities for owners of the Yamaha BW200, covering all critical aspects for keeping the machine in optimal condition.
📋 Manual Details
Coverage Areas
Applicable Years:
1985, 1986, 1987, 1988, 1989
Page Count
Total Pages:
217
Manual Type
Type:
Factory Repair Manual / Service Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Full teardown and rebuild procedures, piston, cylinder, crankshaft, connecting rod, valve clearance adjustment, compression ratio.
Fuel System:
Carburetor (carb, carburettor) overhaul, jetting information (pilot jet, main jet, mixture screw), fuel pump, fuel tank, fuel injection (PGM-FI - though unlikely for this model, the tag implies potential coverage aspects).
Ignition System:
Stator, magneto, electrical troubleshooting (no spark), ignition timing.
Drivetrain:
Transmission, primary reduction gear, clutch, drive shaft, gearshift, linkage, swingarm (swinger), rear drive (wheel).
Suspension:
Front forks, rear suspension (strut, struts), linkage components, suspension adjustments.
Brakes:
Front and rear brake systems, brake levers, brake pedals, brake pads, rotors, brake fluid, hydraulic systems.
Electrical System:
Lighting (headlights, taillights), battery, charging system (rectifier, regulator), switches, throttle cable, starter, kicker, flywheel.
Body And Frame:
Frame, fenders, plastics, seat, handlebars (bars), body panels.
Procedures Included
Maintenance:
Scheduled maintenance, lubrication (viscosity of engine oil), fluid changes (change coolant), tire pressure, spark plug inspection/replacement.
Troubleshooting:
Comprehensive troubleshooting guides for common problems (e.g., no spark, starting issues), error code identification (though less common for this era, tags suggest general error handling).
Repair And Rebuild:
Complete engine overhaul, transmission rebuild, suspension repair, electrical component repair, brake system service.
Diagnostics:
Diagnostic procedures for various systems, identifying faults, checking component functionality.
Installation:
Instructions for installing various parts and accessories.
Technical Depth
Depth:
Full factory specifications, detailed diagrams, torque specifications, step-by-step repair procedures, electrical schematics.
📊 Manual Specifications
File Format
Format Details:
High-quality PDF, searchable text, no printing or saving restrictions.
Print Quality
Image Resolution:
Excellent (implied by 'pictures and part diagrams')
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Quality:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Four-stroke, SOHC, air-cooled
Displacement:
195 cc (11.89 cubic inches)
Bore X Stroke:
67.0 mm x 55.7 mm
Compression Ratio:
9.5:1 (Typical for this era)
Performance
Horsepower:
Approx. 15-17 HP (Estimated, not explicitly stated in product info)
Torque:
N/A (Requires specific manual data)
Fuel System
Carburetor Model:
Mikuni VM series (likely 30mm or similar, specific model in manual)
Fuel Type:
Unleaded Gasoline
Lubrication
Oil Type:
Yamaha recommends specific motorcycle oil (e.g., 10W-30 or 20W-40, consult manual for exact viscosity and API classification).
Engine Components
Valve Train:
SOHC, 2 valves per cylinder
🔧 Transmission
Standard
Transmission Type:
5-speed constant mesh
Optional
Transmission Options:
N/A
Features
Drive System:
Chain drive
Clutch Type:
Wet, multi-plate
📐 Dimensions
Exterior
Overall Length:
Approx. 75.2 inches (1910 mm)
Overall Width:
Approx. 32.1 inches (815 mm)
Overall Height:
Approx. 42.1 inches (1070 mm)
Wheelbase:
Approx. 49.6 inches (1260 mm)
Cargo
Cargo Capacity:
N/A (Motorcycle)
Weights
Dry Weight:
Approx. 271 lbs (123 kg)
Fuel Capacity:
Approx. 2.1 gallons (8.0 liters)
🛡️ Safety Features
Ratings
Safety Certification:
N/A (Motorcycle, standards vary by region)
Active Features
Braking System:
Front: Drum brake; Rear: Drum brake. (Some later models might have disc brakes, verify with specific manual data for exact components).
Passive Features
Lighting:
Headlight, taillight, brake light.
💡 Technology Features
Infotainment
Infotainment System:
N/A (Basic motorcycle design)
Driver Assistance
Assistance Features:
N/A
Connectivity
Connectivity Options:
N/A
🔧 Maintenance
Service Intervals
Oil Change Interval:
Refer to manual for specific mileage/time intervals, typically every 1,000-2,000 miles or annually.
Air Filter Cleaning:
Recommended periodically, especially after dusty riding. Consult manual for specific intervals and cleaning procedures.
Spark Plug Replacement:
Refer to manual for recommended intervals, typically 3,000-6,000 miles.
Fluid Specifications
Brake Fluid:
DOT 3 or DOT 4 (Consult manual for specific recommendation and type, e.g., DOT 3, DOT 4).
Coolant Type:
Ethylene glycol-based permanent antifreeze (typically a 50/50 mix with distilled water). Consult manual for exact specifications.
Known Issues
Common Problems:
Carburetor gumming due to infrequent use or stale fuel, electrical connection corrosion, wear on wide tires, potential carburetor jetting issues in different altitudes/conditions.
Technical Tips
Storage Preparation:
The manual would provide detailed instructions for long-term storage, including fuel stabilizer, battery tender, and proper cleaning.
📚 Vehicle History
Brand Heritage
Manufacturer:
Yamaha Motor Corporation
Model Evolution
Bw Series Development:
The BW series was a niche product designed for exceptional off-road capability, particularly in soft terrain, due to its distinctive fat tires. It was a unique offering in Yamaha's lineup.
Production
Manufacturing Location:
Japan (Typical for Yamaha at this time)
🏆 Awards & Recognition
Recognitions
Industry Awards:
N/A (Not typically awarded for specific models in this category/era, but known for its unique design and capability).
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