Model Years Covered:
1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999
Primary Region Of Operation:
Designed for North American market, but applicable globally where TW200 is sold.
Estimated Page Count:
Approximately 300-400 pages (typical for this era's service manuals, exact count not provided in product description).
Type:
Service Repair Manual
Format:
Likely Printed Manual (as per traditional service manual sales, can be available in digital PDF format).
Engine Mechanical:
Complete disassembly, inspection, repair, and reassembly of the engine, including cylinder, piston, crankshaft, camshaft, valves, timing system, and oil lubrication.
Fuel System:
Carburetor tuning, cleaning, and overhaul; fuel tank and fuel line maintenance.
Ignition System:
Spark plug, ignition coil, CDI unit, wiring diagrams, troubleshooting ignition issues.
Transmission And Clutch:
Clutch operation, adjustment, and replacement; transmission gear inspection, maintenance, and repair; shift mechanism.
Electrical System:
Complete wiring diagrams, lighting system, battery maintenance, charging system (alternator/stator), starter system, switches, and fuses.
Suspension System:
Front fork disassembly, seal replacement, oil levels, and adjustment; rear shock absorber maintenance and replacement.
Braking System:
Front and rear brake system maintenance, including brake shoe/pad replacement, drum/disc inspection, brake fluid replacement, and bleeding.
Wheel And Tire System:
Tire pressure, inspection, and replacement; wheel bearing maintenance; spoke adjustment (if applicable); rim inspection.
Frame And Bodywork:
Frame inspection for damage, handlebar, seat, fenders, and plastic component removal and installation.
Exhaust System:
Exhaust pipe and muffler inspection, maintenance, and removal/installation.
Routine Maintenance:
Oil changes, filter replacements, chain adjustment, lubrication points, brake checks, tire checks, and general inspection.
Troubleshooting:
Diagnostic procedures for common performance issues, starting problems, electrical faults, and mechanical failures.
Repair Procedures:
Step-by-step instructions for component repair and replacement across all major motorcycle systems.
Technical Specifications:
Torque specifications, clearances, fluid capacities, electrical resistance values, and diagnostic data.
Rebuild Instructions:
Detailed guidance for complete engine and transmission rebuilds.
Wiring Diagrams:
Comprehensive electrical schematics for all model years covered.
Depth:
Comprehensive: Covers everything from basic routine maintenance to complete engine overhaul and advanced electrical diagnostics.
User Level:
Suitable for DIY mechanics, independent repair shops, and dealership technicians.
Engine Type:
Air-cooled, four-stroke, SOHC, two-valve
Displacement:
196 cc (for most TW200 models)
Bore X Stroke:
67.0 mm x 55.7 mm (typical for this era and displacement)
Compression Ratio:
9.5:1 (typical)
Horsepower:
Approximately 14-16 HP (varies slightly by year and tuning)
Torque:
Approximately 14-15 Nm (varies slightly by year and tuning)
Carburetor Type:
Mikuni VM series (e.g., VM26 or similar single-barrel carburetor)
Fuel Tank Capacity:
Approximately 7.0 liters (1.8 US gal)
Oil Type:
Yamalube 4 (or equivalent API SE, SF, SG service classification, SAE 10W-30 or 10W-40 recommended)
Oil Capacity With Filter Change:
Approximately 1.4 liters (1.5 US qt)
Overall Length:
Approximately 2,095 mm (82.5 in)
Overall Width:
Approximately 840 mm (33.1 in) (including handlebars)
Overall Height:
Approximately 1,115 mm (43.9 in)
Seat Height:
Approximately 785 mm (30.9 in)
Wheelbase:
Approximately 1,330 mm (52.4 in)
Dry Weight:
Approximately 127 kg (280 lbs)
Wet Weight:
Approximately 134 kg (295 lbs) (with all fluids)
Front Tire Size:
130/80-18M/C 63P (with unique wide profile)
Rear Tire Size:
180/80-14M/C 59P (with unique wide profile)
Front Tire Pressure:
200 kPa (2.0 kgf/cm², 29 psi)
Rear Tire Pressure:
25 kPa (0.25 kgf/cm², 3.6 psi) (for normal road use, lower for off-road)
Engine Oil Change Interval:
Every 3,000 km (1,800 miles) or 6 months, whichever comes first.
Air Filter Cleaning Interval:
Every 2,000 km (1,200 miles) or 6 months, more frequently in dusty conditions.
Spark Plug Replacement Interval:
Inspect every 6,000 km (3,700 miles), replace as needed. Check gap regularly.
Chain Lubrication And Adjustment Interval:
Lubricate every 1,000 km (600 miles) or after riding in rain. Adjust free play as needed (typically 15-25mm).
Valve Clearance Inspection Interval:
Every 12,000 km (7,500 miles) or 12 months.
Engine Oil Specification:
SAE 10W-30 or 10W-40 API SE, SF, SG, or higher classification.
Brake Fluid Specification:
DOT 3 or DOT 4 brake fluid.
Fork Oil Specification:
Yamaha Fork Oil (or equivalent SAE 10W suspension fluid).
Common Wear Items:
Brake shoes, clutch plates, chain and sprockets, carburetor jets, fork seals.
Potential Electrical Issues:
Wiring harness wear, stator coil failure (though generally reliable).
Carburetor Maintenance:
May require periodic cleaning and adjustment, especially if the motorcycle sits for extended periods.
Manufacturer Heritage:
Yamaha Motor Company is a globally recognized leader in motorcycles, marine products, and other motorized vehicles, known for innovation and quality.
Tw200 Design Philosophy:
The TW200 was designed as a versatile dual-purpose motorcycle, excelling in off-road capability with its wide tires and user-friendly nature, making it popular for trail riding and general recreation.
Production Period Covered:
1987-1999, representing the initial generation of the TW200 model.
