Engine Service:
Detailed procedures for engine disassembly, inspection, repair, and reassembly of the 195cc, 4-stroke, air-cooled engine.
Fuel System Service:
Carburetor tuning, cleaning, overhaul, fuel tank, fuel lines, and fuel pump (if applicable).
Ignition System Service:
Spark plug, ignition coil, CDI unit, wiring diagrams, and timing specifications.
Transmission Service:
Clutch operation, gearbox inspection, lubrication, and gear shift mechanism.
Drivetrain Service:
Chain adjustment, lubrication, sprockets, and rear wheel hub.
Suspension Service:
Front fork overhaul, seal replacement, oil levels, rear shock absorber inspection and replacement.
Braking System Service:
Front and rear brake adjustment, pad/shoe inspection and replacement, hydraulic fluid (if applicable), and cable maintenance.
Electrical System Service:
Battery maintenance, lighting system, starter motor, charging system (stator/generator), and comprehensive wiring diagrams.
Chassis And Frame Service:
Frame inspection, steering head bearing adjustment, swingarm service, and mounting points.
Bodywork And Trim Service:
Fender removal/installation, seat, fuel tank mounting, and other cosmetic components.
Preventative Maintenance:
Regular service intervals, lubrication points, and checks for wear and tear.
Troubleshooting Guides:
Diagnostic procedures for common starting, running, and electrical issues.
Repair Procedures:
Step-by-step instructions for component repair and replacement.
Overhaul Procedures:
Detailed guides for major component overhauls (e.g., engine, carburetor).
Wiring Diagrams:
Complete electrical schematics for all model variations within the covered years.
Diagnostic Capabilities:
Covers basic to intermediate diagnostic procedures for common mechanical and electrical faults.
Component Rebuilds:
Includes detailed instructions for rebuilding key components like the engine and carburetor.
Specification Data:
Provides essential technical specifications, torque values, clearances, and tolerances.
Digital Format Quality:
If digital (PDF), expected to be searchable text with high-resolution diagrams. Original printed manuals may be scanned.
Diagram Clarity:
High-quality diagrams and illustrations essential for repair procedures.
Binding Style:
Likely a comb-bound or saddle-stitched booklet for printed versions, designed for workshop use.
Paper Quality:
Durable paper stock suitable for workshop environments, often with glossy pages for diagrams.
Engine Type:
195cc, Air-Cooled, 4-Stroke, SOHC, Single Cylinder
Bore X Stroke:
66.0 mm x 57.9 mm
Valve Clearance Intake:
0.08 - 0.13 mm (0.003 - 0.005 in)
Valve Clearance Exhaust:
0.10 - 0.15 mm (0.004 - 0.006 in)
Horsepower Estimated:
Approximately 15-17 HP (actual figures vary by year and specific model tune)
Torque Estimated:
Approximately 11-13 lb-ft (actual figures vary by year and specific model tune)
Carburetor Model:
Mikuni VM Series (specific model may vary, e.g., VM26)
Fuel Type:
Unleaded gasoline
Fuel Tank Capacity:
Approximately 1.6 US gal (6.0 L)
Overall Length:
Approximately 80.5 inches (2045 mm)
Overall Width:
Approximately 33.1 inches (840 mm)
Overall Height:
Approximately 43.9 inches (1115 mm)
Wheelbase:
Approximately 51.4 inches (1305 mm)
Ground Clearance:
Approximately 10.2 inches (260 mm)
Dry Weight:
Approximately 258 lbs (117 kg)
Front Tire Size:
180/80-14 M/C 59P (wide profile)
Rear Tire Size:
140/80-18 M/C 70P (wide profile)
Oil Change Interval:
Every 1,000 - 1,500 miles (1,600 - 2,400 km) or 6 months, whichever comes first.
Air Filter Cleaning:
Clean every 1,000 miles (1,600 km), replace as needed.
Spark Plug Replacement:
Inspect every 2,000 miles (3,200 km), replace as needed.
Engine Oil Type:
Yamalube 4 (or equivalent) SAE 10W-40 API SG or higher, JASO MA
Engine Oil Capacity:
Approximately 1.5 US qt (1.4 L) without filter change; 1.6 US qt (1.5 L) with filter change
Fork Oil Type:
Yamaha Fork Oil G-10 or equivalent (e.g., SAE 10W)
Fork Oil Capacity Per Leg:
Approximately 10.1 US fl oz (300 ml)
Carburetor Gumming:
If left with fuel for extended periods, the carburetor can become gummed up, requiring cleaning and rebuilding.
Slow Speed Handling:
Due to the wide tires, low-speed maneuverability can be challenging for inexperienced riders or in tight off-road situations.
Suspension Softness:
The stock suspension may be considered soft for heavier riders or aggressive off-road use, but it excels at absorbing bumps on trails.
Yamaha Motorcycles:
Yamaha Motor Company is a Japanese manufacturer of motorcycles, marine products, and other motorized equipment, known for innovation and performance.
Tw200 Introduction:
The TW200 was introduced in 1987 and has remained largely consistent in its core design due to its unique niche appeal.
Production Period:
Originally produced from 1987 onwards, with the manual covering models up to at least 1999, and continuing production in subsequent years.