🏷️ Basic Information

Make:

Yamaha

Model:

TW200 Trailway

Engine Code Common:

2JL, 4CS

👋 Introduction

Niche:

Dual-purpose motorcycle known for its unique styling, comfortable ride, and surprising off-road capability, often favored for trail riding and light adventure touring.

Competitors:

Similar displacement dual-sport or trail bikes from Honda (e.g., XR series), Kawasaki (e.g., KLR250), and Suzuki (e.g., DR200).

Tire Configuration:

Distinctive wide rear tire (180/80-14) and standard front tire (2.75-21) contribute to its unique stability and traction characteristics.

Engine Type:

Air-cooled, four-stroke, SOHC, single-cylinder engine providing reliable and tractable power delivery.

Suspension Travel:

Generous suspension travel front and rear designed for off-road comfort and capability.

Seat Height:

Relatively low seat height for its class, enhancing maneuverability and accessibility for a wide range of riders.

📋 Manual Details

Covered Years:

1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009

Approximate Pages:

350-400

Type:

Workshop Service Repair Manual

Language:

English

Format:

Digital Download (PDF)

📖 Manual Coverage

Engine:

Complete engine disassembly, inspection, and reassembly, including cylinder head, piston, crankshaft, camshaft, valve train, oil pump, and cooling system (air-cooled).

Fuel System:

Carburetor (Mikuni VM series) tuning, cleaning, and overhaul, fuel tank, fuel lines, and petcock service.

Ignition System:

CDI ignition system, spark plug specifications, ignition timing, and troubleshooting.

Transmission:

5-speed sequential gearbox, clutch operation and adjustment, gearbox disassembly and reassembly, oil specifications.

Chassis And Frame:

Frame inspection, steering head bearing service, swingarm and rear suspension linkage maintenance.

Front Suspension:

Telescopic front fork service, oil replacement, seal replacement, and adjustment.

Brakes:

Front disc brake system maintenance, rear drum brake service, hydraulic system bleeding, and component replacement.

Wheels And Tires:

Tire specifications (notably the wide rear tire), wheel bearing service, spoke tensioning, and rim maintenance.

Electrical System:

Wiring diagrams, lighting system, battery maintenance, starter system, and charging system (stator, rectifier/regulator).

Bodywork And Trim:

Panel removal and installation, fender service, seat maintenance, and graphic application.

Rear Shock ABSorber:

Monoshock rear suspension service, linkage lubrication, and shock absorber inspection.

Maintenance Tasks:

Regular scheduled maintenance, oil changes, filter replacements, spark plug checks, chain lubrication and adjustment, brake adjustments, and fluid level checks.

Troubleshooting:

Diagnostic procedures for common starting issues, engine performance problems, electrical faults, and brake issues, with symptom-based troubleshooting guides.

Repair Procedures:

Step-by-step instructions for component removal, installation, and repair for all major systems.

Overhaul Instructions:

Detailed guides for engine, carburetor, and transmission overhauls, including critical dimensions and tolerances.

Wiring Diagrams:

Comprehensive electrical schematics for all model years covered, enabling accurate diagnosis and repair of electrical faults.

Depth:

Comprehensive, covering everything from basic adjustments to full engine rebuilds and electrical system diagnostics.

📊 Manual Specifications

File Type:

PDF

Searchability:

Fully searchable text for quick information retrieval.

Image Resolution:

High-resolution images and diagrams for clarity.

Binding:

N/A (Digital Download)

Paper Quality:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Type:

Air-cooled, four-stroke, SOHC, 2-valve, single-cylinder

Displacement:

197 cc

Bore X Stroke:

66.0 mm x 58.0 mm

Compression Ratio:

9.5:1

Horsepower:

Approximately 16-18 hp @ 7,000 rpm (subject to variation by year and specific tuning)

Torque:

Approximately 17-18 Nm @ 5,000 rpm (subject to variation)

Carburetor Type:

Mikuni VM26SS (or similar VM series) single carburetor

Fuel Capacity:

6.0 Liters (1.6 US gal)

🔧 Transmission

Type:

5-speed constant mesh, sequential

Clutch:

Wet, multiple-disc, cable-actuated

Final Drive:

Chain drive

📐 Dimensions

Overall Length:

2,045 mm (80.5 in)

Overall Width:

830 mm (32.7 in)

Overall Height:

1,105 mm (43.5 in)

Seat Height:

790 mm (31.1 in)

Ground Clearance:

240 mm (9.4 in)

Dry Weight:

Approximately 124 kg (273 lbs)

Wet Weight:

Approximately 128 kg (282 lbs) (curb weight)

Wheelbase:

1,340 mm (52.8 in)

🛡️ Safety Features

Safety Features:

Primarily focused on inherent design features for stability and rider control; no formal crash ratings for this vehicle class.

Braking System:

Front: Disc brake; Rear: Drum brake. Designed for predictable stopping power.

Lighting:

Headlight, taillight, brake light, and turn signals for visibility.

💡 Technology Features

Infotainment System:

None (basic motorcycle instrumentation: speedometer, odometer, odometer reset, neutral indicator, high beam indicator).

Assistance Features:

None.

Connectivity Options:

None.

🔧 Maintenance

Engine Oil Change:

Every 3,000 km (1,800 miles) or 6 months, whichever comes first.

Oil Filter Replacement:

Replace with engine oil change.

Air Filter Cleaning:

Every 1,000 km (600 miles).

Spark Plug Check:

Every 3,000 km (1,800 miles).

Chain Lubrication Adjustment:

Every 500 km (300 miles) or as needed.

Valve Clearance Check:

Every 6,000 km (3,600 miles).

Engine Oil Type:

Yamalube 4 (or API SE, SF, SG class) SAE 20W-40 or SAE 10W-30

Engine Oil Capacity:

1.5 Liters (1.6 US qt) without filter change, 1.7 Liters (1.8 US qt) with filter change.

Fork Oil Type:

Yamaha Suspension Oil (or equivalent SAE 5W/10W)

Fork Oil Quantity:

163 ml (5.5 US fl oz) per fork leg

Brake Fluid Type:

DOT 3 or DOT 4

Carburetor Icing:

Can occur in very cold, humid conditions due to fuel vaporization cooling the carburetor body.

Clutch Slippage:

Can occur with age and mileage, particularly if subjected to hard use; manual provides adjustment and replacement procedures.

Rear Suspension Linkage Wear:

Regular lubrication of the rear suspension linkage is critical to prevent premature wear of bearings and bushings.

Speedometer Cable:

Can wear and seize over time, requiring lubrication or replacement.

📚 Vehicle History

Yamaha Motors Co Ltd:

Yamaha has a long history in motorcycle manufacturing, known for innovation in engine design, sound engineering, and performance across various motorcycle segments.

Tw200 Introduction:

The TW200 was introduced as a unique dual-purpose motorcycle emphasizing trail riding and ease of use. Its distinctive styling and wide rear tire have remained largely consistent throughout its production run.

Model Updates:

While the core design remained consistent, minor updates occurred over the years, often related to emissions compliance, color schemes, and component revisions. The manual covers this broad range of evolutionary changes.

Manufacturing Location:

Primarily manufactured in Japan.

🏆 Awards & Recognition

Awards Received:

Not typically associated with specific awards, but recognized for its longevity, reliability, and niche appeal in the dual-sport segment.

Consumer Satisfaction:

Generally high due to its simplicity, durability, and low running costs.