Yamaha TW200 TRAILWAY Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Yamaha Model: TW200 TRAILWAY Codes Internal Model Code: DG07J Engine Code: 2JL 👋 Introduction Market Position Segment: Dual-sport, trail riding, light off-road Target Audience: Enthusiasts,...

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Type: Motorcycle

Vendor:

Sku: 279621

Tags: Motorcycle Motorcycles Speed Triple Triumph TW200 TRAILWAY Yamaha

Product variants

Description

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

TW200 TRAILWAY

Codes

Internal Model Code:

DG07J

Engine Code:

👋 Introduction

Market Position

Segment:

Dual-sport, trail riding, light off-road

Target Audience:

Enthusiasts, owners, mechanics seeking detailed repair and maintenance guidance

Competitive Analysis

Competitors:

Kawasaki KLR250, Suzuki DR200SE, Honda CRF230L

Key Features

Distinctive Features:

Fat tires for superior traction and comfort, simple and robust engineering

Manual Value Proposition:

Ensures completeness and accuracy, avoiding the pitfalls of incomplete or low-quality alternatives

📋 Manual Details

Coverage Areas

Main Coverage:

Comprehensive Service and Repair

Secondary Coverage:

Troubleshooting, Maintenance, Diagnostics

Page Count

Estimated Pages:

Manual Type

Type:

Workshop Service Manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine:

Complete overhaul, tuning, lubrication, cooling, fuel system (carburetor), exhaust

Transmission:

Clutch, gearbox, final drive inspection and repair

Chassis:

Frame, swingarm, steering system, suspension (front forks, rear shock absorber)

Electrical:

Ignition system, lighting, charging system (stator, regulator/rectifier), starter motor, wiring diagrams

Brakes:

Front and rear brake systems, hydraulic components, bleeding procedures

Wheels And Tires:

Tire mounting, wheel bearing service, spoke tensioning

Procedures Included

Maintenance:

Regular servicing, oil changes, filter replacements, chain adjustment, spark plug service

Troubleshooting:

Diagnostic charts for common problems and their solutions

Repair:

Step-by-step repair instructions for all major components

Disassembly Assembly:

Detailed instructions for component removal and reinstallation

Technical Depth

Depth:

Comprehensive, covering routine maintenance to complete engine rebuilds and electrical system diagnostics

📊 Manual Specifications

File Format

PDF Quality:

High-resolution, printable, searchable text

Print Quality

Scalability:

Excellent for printing individual pages or entire sections

Binding Type

Digital Binding:

N/A (Digital Format)

Paper Type

Digital Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Four-stroke, SOHC, air-cooled, single-cylinder

Displacement:

197 cc (12.0 cu. in.)

Bore X Stroke:

66.0 mm x 58.0 mm (2.60 in x 2.28 in)

Compression Ratio:

9.5:1

Performance

Horsepower:

Approx. 16.5 HP @ 7500 rpm (model dependent)

Torque:

Approx. 16.0 Nm (11.8 ft-lb) @ 6000 rpm (model dependent)

Fuel System

Carburetor:

Mikuni VM26, 26 mm, single

Fuel Type:

Unleaded gasoline, octane rating 87 or higher

Lubrication

Oil Type:

Yamalube 4 (or equivalent SAE 20W-40 API SE, SF, SG type, API SG or higher)

Oil Capacity:

1.50 L (1.58 US qt, 1.32 Imp qt) without filter change; 1.70 L (1.79 US qt, 1.50 Imp qt) with filter change

Ignition

Ignition System:

CDI (Capacitor Discharge Ignition)

Spark Plug Type:

NGK CR6HSA or DENSO U20FSR-U

Spark Plug Gap:

0.6-0.7 mm (0.024-0.028 in)

🔧 Transmission

Standard

Transmission Type:

Constant mesh 5-speed

Clutch Type:

Wet, multiple-disc

Final Drive:

Chain drive

Features

Gear Ratios:

Refer to manual for specific ratios

Transmission Oil Type:

Yamalube 4 (or equivalent SAE 10W-30 API SE, SF, SG type)

Transmission Oil Capacity:

0.65 L (0.69 US qt, 0.57 Imp qt)

📐 Dimensions

Exterior

Length:

2,085 mm (82.1 in)

Width:

825 mm (32.5 in)

Height:

1,120 mm (44.1 in)

Wheelbase:

1,355 mm (53.3 in)

Ground Clearance:

265 mm (10.4 in)

Seat Height:

805 mm (31.7 in)

Weights

Dry Weight:

118 kg (260 lbs)

Wet Weight:

124 kg (273 lbs) (approx.)

Fuel Tank Capacity:

7.0 L (1.8 US gal, 1.5 Imp gal)

Wheels And Tires

Front Tire Size:

130/80-18M/C 63P

Rear Tire Size:

180/80-14M/C 62P

Front Suspension:

Telescopic fork

Front Fork Travel:

150 mm (5.9 in)

Rear Suspension:

Swingarm (Monocross suspension)

Rear Shock Travel:

140 mm (5.5 in)

Wheel Type:

Spoked, 18-inch front, 14-inch rear

🛡️ Safety Features

Ratings

Crash Test Ratings:

N/A (Motorcycle)

Active Features

Braking System:

Front: 220 mm Disc, Rear: 110 mm Drum

Lighting:

Halogen headlight, LED taillight

Passive Features

Frame Construction:

Steel diamond frame

💡 Technology Features

Infotainment

Dashboard:

Analog speedometer, odometer, turn signal indicators, neutral indicator, high beam indicator

Driver Assistance

Not equipped

Connectivity

Bluetooth:

Not equipped

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000 km (2,000 miles) or 6 months

Air Filter Cleaning:

Every 6,000 km (4,000 miles)

Spark Plug Replacement:

Every 12,000 km (7,500 miles)

Valve Clearance Check:

Every 12,000 km (7,500 miles)

Chain Lubrication Adjustment:

Every 1,000 km (600 miles) or after washing/rain

Fluid Specifications

Engine Oil Viscosity:

SAE 20W-40 API SE, SF, SG or higher

Transmission Oil Viscosity:

SAE 10W-30 API SE, SF, SG

Brake Fluid Type:

DOT 3

Known Issues

Common Wear Items:

Clutch plates, tires, brake pads, chain and sprockets

Carburetor Tuning:

Can require periodic adjustment for optimal performance, especially at altitude changes.

📚 Vehicle History

Brand Heritage

Manufacturer:

Yamaha Motor Corporation

Origins:

Founded in 1955, renowned for motorcycles, musical instruments, and marine products.

Model Evolution

Introduction Year:

Key Changes:

Minor updates over its production run, maintaining its core design and functionality.

Production

Manufacturing Location:

Japan

🏆 Awards & Recognition

Recognitions

General Reputation:

Highly regarded for its durability, simplicity, and go-anywhere capability, earning it a loyal following.