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Yamaha TRAILWAY TW200 2001 2002 2003 2004 2005 2006 2007 2008 2009 Service Owners Workshop Shop Repair Manual

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🏷️ Basic Information Identification Make: Yamaha Model: TW200 TRAILWAY Product Type: Service/Owner's/Workshop/Repair Manual 👋 Introduction Market Position Vehicle Category: Dual-sport motorcycle, known for its ruggedness, simplicity, and off-road capability. Competitive...
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Type: Motorcycle
Vendor:
Yamaha
Sku: 491565
Tags: 2001 2002 2003 2004 2005 2006 2007 2008 2009 Motorcycle Motorcycles Speed Triple TRAILWAY TW200 Triumph Yamaha
Yamaha TRAILWAY TW200 2001 2002 2003 2004 2005 2006 2007 2008 2009 Service Owners Workshop Shop Repair Manual
🏷️ Basic Information
Identification
Make:
Yamaha
Model:
TW200 TRAILWAY
Product Type:
Service/Owner's/Workshop/Repair Manual
👋 Introduction
Market Position
Vehicle Category:
Dual-sport motorcycle, known for its ruggedness, simplicity, and off-road capability.
Competitive Analysis
Key Competitors:
Honda CRF230F, Kawasaki KLX230, Suzuki DR-Z200.
Key Features
Unique Selling Points:
Extremely wide 'fat' tires for superior traction and stability on varied terrain, low seat height for accessibility, simple and reliable air-cooled engine.
Target Audience
Intended Riders:
Beginners, trail riders, commuters seeking an economical and versatile motorcycle, riders prioritizing ease of use and durability.
📋 Manual Details
Coverage Areas
Years Covered:
2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009
Page Count
Estimated Pages:
400-600
Manual Type
Manual Classification:
Comprehensive Service and Owner's Manual
Language
Language:
English
Format
Delivery Format:
Digital Download (PDF)
📖 Manual Coverage
Systems Covered
Engine:
Detailed inspection, disassembly, assembly, troubleshooting, and tuning of the 196cc air-cooled, four-stroke engine.
Fuel System:
Carburetor (Mikuni VM series) adjustment, cleaning, rebuilding, fuel pump, fuel lines, and fuel tank maintenance.
Ignition System:
CDI ignition system, spark plug specifications, timing checks, and component testing.
Transmission:
Clutch operation, gear shifting mechanism, internal transmission components, oil change procedures, and troubleshooting.
Drivetrain:
Chain adjustment, lubrication, sprocket wear inspection, and rear differential (if applicable, though TW200 is typically chain drive).
Suspension:
Front telescopic forks (oil change, seal replacement, spring inspection), rear monoshock absorber, linkage maintenance, and adjustments.
Brakes:
Front and rear disc brake systems, hydraulic fluid replacement, caliper service, brake pad inspection and replacement, and bleeding procedures.
Electrical System:
Wiring diagrams, battery maintenance, charging system (stator, regulator/rectifier), lighting (headlight, taillight, indicators), horn, starter motor, and fuses.
Cooling System:
N/A (Air-cooled engine)
Exhaust System:
Muffler, header pipe inspection, gasket replacement, and noise level checks.
Chassis And Frame:
Frame inspection, steering head bearing service, swingarm maintenance, and footpeg mounting.
Bodywork And Trim:
Fender removal and installation, seat, fuel tank mounting, side covers, and handlebar assembly.
Procedures Included
Preventive Maintenance:
Oil changes, filter replacements, chain lubrication, brake adjustments, tire pressure checks, spark plug replacement, valve clearance checks.
Troubleshooting:
Diagnostic flowcharts for common problems like starting issues, poor performance, strange noises, and electrical faults.
Repair Procedures:
Step-by-step instructions with diagrams for component removal, overhaul, and reinstallation (e.g., engine rebuild, carburetor tuning, suspension overhaul).
Adjustments:
Carburetor idle speed and mixture, clutch free play, throttle cable tension, brake lever free play, chain slack.
Diagnostics:
Methods for testing electrical components (coils, sensors, lighting), engine performance checks, and identifying mechanical issues.
Technical Depth
Diagnostic Level:
Advanced diagnostic procedures for engine, electrical, and mechanical systems.
Rebuild Instructions:
Complete engine and major component rebuilding procedures with torque specifications and clearances.
Electrical Schematics:
Detailed, high-resolution wiring diagrams for all electrical systems.
Special Tools:
Identification of required special tools and their application.
📊 Manual Specifications
File Format
Format Details:
Searchable PDF document, allowing for quick navigation and keyword searches.
Print Quality
Image Resolution:
High-resolution images and clear, crisp text for easy readability and accurate reproduction of diagrams.
Binding Type
Binding Style:
N/A (Digital Download)
Paper Type
Paper Quality:
N/A (Digital Download) - Printable on standard paper.
⚙️ Engine Specifications
Primary Engine
Engine Type:
Air-cooled, 4-stroke, SOHC, 2-valve
Displacement:
196 cc (12.0 cubic inches)
Bore X Stroke:
67.0 mm x 55.7 mm (2.64 in x 2.19 in)
Compression Ratio:
9.5:1
Performance
Horsepower Est:
Approx. 16-17 HP @ 7500 RPM
Torque Est:
Approx. 11-12 lb-ft @ 6000 RPM
Fuel System
Carburetor Model:
Mikuni VM26SS
Fuel Capacity:
2.3 US gal (8.7 L)
Fuel Type:
Unleaded gasoline, 87 octane or higher recommended.
🔧 Transmission
Standard
Transmission Type:
5-speed constant mesh
Clutch Type:
Wet, multiple-disc
Features
Final Drive:
Chain drive
Transmission Oil Type:
Yamalube 4 (or equivalent SAE 20W-40 API SG or higher motorcycle oil)
Transmission Oil Capacity:
1.0 US qt (0.94 L)
📐 Dimensions
Exterior
Length:
80.7 in (2050 mm)
Width:
32.1 in (815 mm)
Height:
44.1 in (1120 mm)
Wheelbase:
51.5 in (1310 mm)
Ground Clearance:
6.7 in (170 mm)
Seat Height:
31.9 in (810 mm)
Weights
Dry Weight:
262 lbs (119 kg)
Curb Weight:
278 lbs (126 kg)
Tires
Front Tire Size:
130/80-18 M/C 66P
Rear Tire Size:
180/80-14 M/C 77P
Wheels
Front Wheel Type:
Spoked, 18-inch
Rear Wheel Type:
Spoked, 14-inch
🛡️ Safety Features
Ratings
Crash Test Ratings:
N/A (Motorcycle specific safety is assessed differently than automobiles)
Active Features
Braking System:
Hydraulic disc brakes front and rear for enhanced stopping power.
Lighting:
Halogen headlight, taillight, and bright LED turn signals for visibility.
Passive Features
Frame Construction:
Durable steel frame designed for off-road resilience.
Tire Design:
Wide profile tires offer increased stability and grip, reducing the likelihood of slides.
💡 Technology Features
Infotainment
Infotainment Systems:
N/A (Basic motorcycle design focused on function).
Driver Assistance
Advanced Features:
N/A (Focus on simplicity and mechanical reliability).
Connectivity
Connectivity Options:
N/A.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 3,000 miles (4,800 km) or 6 months, whichever comes first. Initial change at 600 miles (1000 km).
Spark Plug Replacement:
Every 6,000 miles (9,600 km).
Air Filter Cleaning:
Every 1,500 miles (2,400 km), clean and re-oil. Replace as needed.
Valve Clearance Check:
Every 6,000 miles (9,600 km).
Chain Maintenance:
Clean and lubricate chain every 500 miles (800 km) or after riding in wet/dirty conditions. Adjust tension as needed (10-20mm free play).
Fluid Specifications
Engine Oil Specification:
Yamalube 4 (or equivalent SAE 20W-40 API SG or higher motorcycle oil)
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid.
Fork Oil Type:
Yamaha Fork Oil 10W (or equivalent SAE 10W suspension fluid)
Fork Oil Capacity:
Approximately 450 ml (15.2 US oz) per fork leg.
Known Issues
Common Wear Items:
Chain and sprockets, brake pads, tires (especially the wide rear tire), carburetor jets due to ethanol fuel.
Potential Problems:
Carburetor gumming if fuel is left for extended periods, potential for weak spark from CDI unit over time, rear shock absorber degradation.
📚 Vehicle History
Brand Heritage
Manufacturer Origin:
Yamaha Motor Company, Japan.
Company Focus:
Renowned for musical instruments and a wide range of powered products including motorcycles, marine engines, and robotics.
Model Evolution
Introduction Year:
1987 (TW200)
Key Design Philosophy:
Emphasis on low-end torque, off-road usability, and a unique, user-friendly design with its distinctive wide tires.
Production
Manufacturing Location:
Primarily Japan.
Model Continuity:
The TW200 has seen minimal major changes since its introduction, a testament to its successful and enduring design.
🏆 Awards & Recognition
Recognitions
Industry Recognition:
Consistently praised for its unique design, off-road capability, and learner-friendly nature.
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