Product Name:
Yamaha TW200 Trailway Workshop Repair Manual 1987-2009
Engine Codes:
Not explicitly stated in product info, but likely includes 2JL, 5NW, 5VE for various iterations.
Chassis Codes:
Not explicitly stated in product info, but likely includes various chassis designations for different model years.
Positioning:
The Yamaha TW200 Trailway is a niche dual-sport motorcycle known for its incredible fat tires and go-anywhere capability, particularly suited for off-road trails, sand, and general light-duty trail riding. Its rugged simplicity and ease of maintenance make it popular among beginners and experienced riders alike who prioritize fun and utility over high performance.
Competitors:
Competes with other small-displacement dual-sport or trail-oriented motorcycles such as the Suzuki VanVan (although often with a slimmer tire), and some smaller displacement dual-sport offerings from Honda (like older XR models) or Kawasaki (like the KLR250, though more performance-oriented).
Distinctive Features:
The most defining feature is its unusually wide tires, providing excellent traction and stability on soft terrain. Its lightweight, simple construction, and reliable air-cooled engine contribute to its accessibility and low maintenance requirements.
Value:
This workshop manual is an indispensable resource for owners and technicians seeking to maintain, diagnose, and repair the TW200 Trailway. By providing the same level of detail as factory-issued manuals, it empowers users to perform complex tasks accurately, saving time and money on dealership repairs.
Years Covered:
1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009
Regions Covered:
Global (likely covers specifications and procedures applicable to major markets where the TW200 was sold, including North America, Europe, and Asia).
Page Count:
Not explicitly stated, but typical professional workshop manuals for this era and coverage range from 300 to 600+ pages.
Manual Type:
Workshop Service & Repair Manual
Language:
English (standard for professional workshop manuals of this nature).
Format:
Digital Download (PDF)
Engine Mechanical:
Complete engine overhaul, cylinder head, pistons, crankshaft, camshaft, valve timing, lubrication system, cooling system (air-cooled specifics).
Fuel System:
Carburetor service and adjustment (likely Mikuni BS series), fuel tank, fuel lines, petcock operation.
Ignition System:
CDI ignition, spark plug specifications, ignition timing, stator and pickup coil testing.
Transmission Drivetrain:
Clutch operation and adjustment, gearbox disassembly and reassembly, gear ratios, drive chain maintenance and adjustment.
Electrical System:
Wiring diagrams for all circuits, battery specifications, charging system (generator/stator), lighting system (headlight, taillight, signals), starting system (starter motor, solenoid), instrument cluster.
Suspension System:
Front fork service, oil seals, springs, rear shock absorber service, linkage maintenance.
Braking System:
Front and rear brake systems (likely drum brakes with potential disc brake variations on later models), brake pad/shoe inspection and replacement, brake fluid specifications, bleeding procedures.
Wheel Tire Assembly:
Tire specifications, wheel bearing maintenance, spoke tensioning and truing (critical for off-road bikes), rim specifications.
Frame Bodywork:
Frame inspection, body panel removal and installation, seat, fenders, handlebars, controls (levers, cables).
Routine Maintenance:
Oil changes, filter replacements, chain lubrication and adjustment, brake checks, tire pressure checks, bolt torque checks.
Troubleshooting:
Diagnostic flowcharts, common problems and their solutions, electrical system diagnostics, engine performance issues.
Repair Rebuild:
Step-by-step instructions for component disassembly, inspection, repair, and reassembly for all major systems.
Inspection Checks:
Detailed procedures for inspecting wear and tear on critical components, safety checks.
Depth:
Comprehensive, covering everything from basic fluid changes to complete engine and transmission overhauls. Includes detailed technical specifications, diagrams, and torque values.
Engine Type:
Air-cooled, 4-stroke, SOHC, 2-valve
Displacement:
196 cc (Cubic Centimeters)
Bore X Stroke:
67.0 mm x 55.7 mm (Typical for the 2JL engine code)
Compression Ratio:
9.5:1 (Typical)
Carburetor Type:
Mikuni BS26 (Typical, single constant velocity carburetor)
Horsepower:
Approximately 15-17 HP (Varies slightly by year and tuning)
Torque:
Approximately 10-12 lb-ft (Varies slightly by year and tuning)
Fuel Type:
Unleaded gasoline
Fuel Tank Capacity:
Approx. 6.5 Liters (1.7 Gallons)
Overall Length:
Approx. 2055 mm (80.9 in)
Overall Width:
Approx. 845 mm (33.3 in)
Overall Height:
Approx. 1115 mm (43.9 in)
Wheelbase:
Approx. 1330 mm (52.4 in)
Seat Height:
Approx. 800 mm (31.5 in)
Dry Weight:
Approx. 127 kg (280 lbs)
Curb Weight:
Approx. 133 kg (293 lbs) (Includes all necessary fluids and a full tank of fuel)
Maximum Load Capacity:
Not explicitly stated but designed for single rider primarily, with allowance for moderate luggage.
Front Tire:
130/80-18 M/C 66P (Wide tire)
Rear Tire:
180/80-14 M/C 62P (Extra wide tire)
Safety Certifications:
Meets relevant safety standards for motorcycles in its class and production era (e.g., DOT, EPA).
Active Safety:
Dependence on rider skill, wide tires for stability. No advanced electronic rider aids like ABS or traction control.
Passive Safety:
Durable frame, adequate lighting, reflector placement. The manual will detail procedures for ensuring all safety systems are functioning correctly.
Infotainment System:
None (basic analogue instrumentation: speedometer, odometer, neutral indicator, high beam indicator).
Driver Assistance Features:
None. The vehicle's design prioritizes simplicity and direct rider input.
Connectivity Features:
None. Focus is on mechanical and electrical operation.
Oil Change Interval:
Typically every 3,000-5,000 km (1,800-3,000 miles) or annually, whichever comes first. The manual will specify exact intervals and oil type.
Chain Maintenance:
Lubrication and adjustment every 500-1,000 km (300-600 miles). Manual will detail correct slack and lubrication procedures.
Valve Clearance Check:
Typically every 6,000-10,000 km (4,000-6,000 miles). Critical adjustment procedure detailed in the manual.
Engine Oil Type:
Yamalube 4 (or equivalent) SAE 10W-40 API SE, SF or SG (The manual will specify the exact Yamaha recommendation and API rating).
Engine Oil Capacity:
Approx. 1.5 Liters (with filter change). Manual confirms exact capacity.
Fork Oil Type:
Yamaha Fork Oil G-10 or equivalent SAE 10W (Manual will specify type and quantity for each fork leg).
Brake Fluid Type:
DOT 3 or DOT 4. Manual will specify.
Common Wear Items:
Tire wear (especially with aggressive use), brake shoes/pads, drive chain and sprockets, clutch wear, fork seal leaks, carburetor jetting issues due to fuel variations or wear.
Electrical Reliability:
Generally reliable, but aging wiring harnesses, loose connections, or failing rectifier/regulators can occur over time. The manual's wiring diagrams are crucial for troubleshooting.
Yamaha Motorcycles:
Yamaha Motor Company has a rich history dating back to its founding in 1955, building a reputation for innovation, reliability, and performance across a wide range of motorcycles, from sportbikes to cruisers and off-road machines.
Tw200 Development:
The TW200 was introduced in the mid-1980s, designed specifically for trail riding and exploring challenging terrain. Its unique tire configuration and simple, robust mechanics have remained largely consistent throughout its production run, speaking to its successful fundamental design. Minor updates typically included cosmetic changes, emissions compliance adjustments, and occasional suspension or brake refinements.
Production Years:
1987-2009 (as covered by this manual). Production has continued beyond 2009 in various forms and markets.
Manufacturing Location:
Primarily manufactured in Japan.
