Motorcycle Segment:
Dual-sport, trail, beginner-friendly motorcycle known for its unique fat tires and ease of use.
Comparable Models:
Suzuki DR200, Honda XR200R, Kawasaki KLR250 (though the TW200 has a distinct niche due to its tires).
Unique Selling Proposition:
Exceptionally wide tires providing excellent traction and stability on varied terrain, including sand and soft ground.
Intended Use:
Light trail riding, recreational off-roading, and urban commuting.
Covered Model Years:
1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999
Primary Covered Year:
1993
Estimated Page Count:
~300-400 pages (typical for a comprehensive service manual of this era)
Manual Type:
Service Manual / Repair Manual
Format:
Likely printed book, potentially available as a PDF digital download
Engine:
Complete engine disassembly, assembly, inspection, tuning, and troubleshooting for the 223cc air-cooled four-stroke single-cylinder engine.
Fuel System:
Carburetor (VM26), fuel tank, fuel lines, fuel filter, and related components servicing and adjustment.
Ignition System:
CDI ignition system, spark plug, ignition coil, and timing adjustments.
Transmission:
Clutch operation, gearbox disassembly and assembly, gear shift mechanism, and internal component inspection.
Drivetrain:
Final drive chain and sprockets maintenance, inspection, and replacement procedures.
Suspension:
Front telescopic forks (including oil change and seal replacement), rear swingarm, and shock absorber maintenance and adjustment.
Brakes:
Front and rear brake system servicing, including caliper, master cylinder, brake pads, brake fluid flush, and adjustment.
Electrical System:
Wiring diagrams, battery maintenance, lighting system (headlight, taillight, turn signals), horn, starter motor, and charging system (stator, rectifier/regulator).
Chassis And Frame:
Frame inspection, handlebar, steering system, and wheel bearing maintenance.
Bodywork:
Fender, seat, fuel tank cover, and related plastic components removal and installation.
Routine Maintenance:
Oil changes, filter replacements, chain lubrication and adjustment, tire pressure checks, spark plug inspection and replacement, air filter cleaning.
Troubleshooting:
Diagnostic procedures for common issues related to starting, engine performance, electrical problems, and braking.
Engine Rebuild:
Detailed instructions for engine disassembly, component inspection, measuring clearances, piston and ring replacement, cylinder honing, and reassembly.
Carburetor Tuning:
Idle speed adjustment, fuel-air mixture settings, and jetting recommendations.
Suspension Service:
Front fork oil replenishment, seal replacement, and rear shock absorber adjustments.
Brake System Overhaul:
Bleeding procedures, caliper seal replacement, and pad replacement.
Electrical Diagnostics:
Using a multimeter to test components, tracing wiring faults, and diagnosing electrical system issues.
Depth Of Coverage:
Comprehensive (from basic maintenance to full engine and component overhauls).
Diagnostic Capabilities:
Includes diagnostic flowcharts and procedures for identifying and resolving malfunctions.
Special Tools:
Lists required special tools and their part numbers for specific repair procedures.
Engine Type:
Air-cooled, four-stroke, SOHC, 2-valve, single-cylinder
Displacement:
223 cc (223cc)
Bore X Stroke:
67.0 mm x 64.0 mm (typical for this model)
Compression Ratio:
9.5:1 (typical for this model)
Horsepower:
~15-17 HP @ ~7000 RPM (estimated, actual may vary slightly by year)
Torque:
~17-19 Nm @ ~5500 RPM (estimated, actual may vary slightly by year)
Carburetor Model:
Mikuni VM26 (single)
Fuel Capacity:
1.6 US gal (6.0 L)
Oil Capacity:
1.1 US qt (1.0 L) without filter change, 1.2 US qt (1.1 L) with filter change (refer to manual for exact amount)
Ignition System:
C.D.I. (Capacitor Discharge Ignition)
Engine Cooling:
Forced Air Cooling
Engine Oil Change:
Every 2,000 km (1,200 miles) or 6 months, whichever comes first. Use of a quality motorcycle-specific oil is crucial.
Oil Filter Change:
Every 4,000 km (2,400 miles) or annually, usually coinciding with an oil change.
Air Filter Cleaning:
Every 2,000 km (1,200 miles) or as needed based on riding conditions. More frequent cleaning is recommended for dusty environments.
Spark Plug Inspection:
Every 4,000 km (2,400 miles). Replacement typically every 8,000-10,000 km (5,000-6,000 miles).
Chain Lubrication:
Every 500-1000 km (300-600 miles) or after riding in wet conditions. Chain adjustment every 1,000-2,000 km (600-1,200 miles).
Engine Oil Type:
SAE 10W-40 API SE or SF (refer to manual for specific viscosity and API classification recommendations).
Brake Fluid Type:
DOT 3 or DOT 4 (refer to manual for specific type, usually DOT 3 for this era).
Fork Oil Type:
Yamaha Suspensio Oil 10W or equivalent (capacity and level critical, consult manual).
Carburetor Cleaning:
The VM26 carburetor can be prone to clogging with age and infrequent use; regular cleaning and proper fuel stabilizer usage are recommended.
Electrical Connections:
Corrosion on electrical connectors can lead to intermittent issues, especially in humid or salty environments. Di-electric grease is beneficial.
Fat Tire Pressure:
Maintaining correct tire pressure is crucial for handling and tire longevity; the unique tires require specific pressures (typically low).
Starter Solenoid:
Can occasionally fail, preventing the starter motor from engaging. Testing and replacement are covered in the manual.
Yamaha Legacy:
Yamaha Motor Company, established in 1955, is renowned for its engineering excellence in motorcycles, musical instruments, and other powered products.
Tw200 Introduction:
The TW200 was introduced in 1987, quickly gaining a reputation for its unique fat tires and go-anywhere capability.
Tw200 Updates:
Minor updates occurred throughout its production run, but the core design and features remained largely consistent from 1987 through 1999 and beyond.
Manufacturing Location:
Japan (typical for Yamaha models of this period)
