Model:
TW200 Trailway / TW200E Trailway
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
Oem Manual Identifier:
Likely corresponds to Yamaha's internal service manual numbering system for this period, though specific OEM part numbers for the manual are not provided in the product description.
Niche:
The Yamaha TW200 Trailway is a unique dual-sport motorcycle known for its distinctive fat rear tire, making it popular for off-road exploration, light trail riding, and urban commuting with a distinctive style. This manual serves owners and mechanics looking to maintain and repair this specialized machine.
Similar Models:
While the TW200 has a unique niche, its dual-sport nature places it in a broad category. Competitors might include other small-displacement dual-sports like the Suzuki VanVan (though often with a narrower tire) or Honda dual-sports, but the TW200's fat-tire configuration is its primary differentiator.
Manual Advantage:
This manual is crucial for owners seeking to perform their own maintenance and repairs, saving significant costs compared to dealership labor. Its digital format ensures accessibility across multiple devices.
Vehicle Appeal:
The TW200 appeals to riders looking for a reliable, easy-to-handle motorcycle with go-anywhere capability thanks to its fat tire, which provides excellent traction on soft surfaces like sand and dirt.
Engine Mechanical:
Engine teardown, assembly, piston, rings, cylinder, crankshaft, connecting rod, valve train, timing, lubrication system, cooling system (air-cooled).
Fuel System:
Carburetor disassembly, cleaning, adjustment, fuel tank, fuel lines, fuel pump (if applicable).
Ignition System:
CDI unit, spark plug, ignition coil, wiring, timing checks.
Electrical System:
Wiring diagrams, battery, charging system (stator, rectifier/regulator), lighting (headlight, taillight, indicators), starting system (starter motor, starter clutch).
Transmission Drivetrain:
Clutch operation, gearbox disassembly/assembly, gear inspection, final drive (chain and sprockets).
Brakes:
Front and rear brake systems (drum or disc depending on specific sub-model year), brake pad/shoe replacement, brake fluid flush, bleeding procedures, caliper/wheel cylinder maintenance.
Suspension:
Front fork overhaul, oil replacement, seal replacement, rear shock absorber inspection and replacement, linkage maintenance.
Steering:
Handlebar, steering stem, steering bearings inspection and adjustment.
Wheels Tires:
Tire inspection, tire pressure, wheel bearing maintenance, spoke tensioning (if applicable), rim runout.
Frame Bodywork:
Frame inspection, plastic body panel removal/installation, seat, fenders, exhaust system.
Routine Maintenance:
Oil changes, filter replacement, air filter cleaning/replacement, spark plug replacement, chain lubrication and adjustment, brake adjustments, tire pressure checks.
Troubleshooting:
Diagnostic charts for common starting, running, and electrical issues.
Disassembly Assembly:
Step-by-step instructions for component removal and installation, including torque specifications.
Rebuilding:
Detailed procedures for overhauling major components like the engine, carburetor, and suspension forks.
Electrical Diagnostics:
Using multimeters, checking circuits, diagnosing charging system issues, starter issues.
Depth Level:
Professional Quality, In-depth. Covers everything from basic maintenance to complete engine rebuilds and complex electrical diagnostics.
Diagnostic Focus:
Provides systematic troubleshooting guides and potential causes for common failures.
Rebuild Specificity:
Includes specific torque values, clearances, and assembly sequences crucial for proper component function.
File Type:
PDF (Portable Document Format)
Searchability:
Likely text-searchable due to being a professional digital download, allowing for quick information retrieval.
Digital Quality:
High resolution for clear viewing and printing of diagrams and text. 'Professional quality' implies excellent clarity.
Binding:
Not applicable for digital download. For printed versions, typically a comb binding or perfect binding.
Paper Quality:
Not applicable for digital download. Original OEM manuals often use durable, matte paper stock to resist grease and wear.
Engine Type:
Four-stroke, SOHC, air-cooled single-cylinder.
Displacement:
196cc (for most models in this range, exact figures may vary slightly by year or specific variant).
Bore X Stroke:
Typically around 66.0 mm x 57.0 mm (subject to verification for specific years).
Compression Ratio:
Around 9.5:1 (subject to verification).
Horsepower Est:
Approximately 15-17 HP at 8,000 RPM (exact figures vary by year and tuning).
Torque Est:
Approximately 11-13 lb-ft at 6,000 RPM (exact figures vary by year).
Carburetor Type:
Mikuni VM Series (e.g., VM26SS or similar). Specific main jet, pilot jet, needle, and jet needle position details will be in the manual.
Fuel Type:
Unleaded gasoline.
Engine Oil Type:
Yamalube 4 (or equivalent SAE 10W-40 or 20W-40 API SG or higher motorcycle oil). Consult manual for exact viscosities based on temperature.
Oil Capacity:
Approximately 1.6 liters (1.7 US qt) with oil filter change. Consult manual for exact capacity with and without filter change.
Oil Filter Part Number Est:
Yamaha P/N 5JX-13440-00-00 or Hiflofiltro HF145 (cross-reference is critical).
Length:
Approx. 2,045 mm (80.5 in).
Width:
Approx. 805 mm (31.7 in) at widest point (handlebar).
Height:
Approx. 1,110 mm (43.7 in).
Wheelbase:
Approx. 1,360 mm (53.5 in).
Ground Clearance:
Approx. 150 mm (5.9 in).
Seat Height:
Approx. 800 mm (31.5 in).
Dry Weight Est:
Approx. 127 kg (280 lbs).
Wet Weight Est:
Approx. 130 kg (287 lbs) (with all fluids).
Fuel Capacity:
Approx. 7.0 liters (1.8 US gal), including reserve.
Front Tire Size:
2.75-21 4PR (or similar tubed tire, bias-ply construction).
Rear Tire Size:
180/80-14M/C 62P (or similar tubed, fat tire, bias-ply construction). The 'fat tire' is a key characteristic.
Front Wheel Type:
Spoked wheel, 21-inch diameter.
Rear Wheel Type:
Spoked wheel, 14-inch diameter, designed to accommodate the wide tire.
Safety Ratings:
Motorcycles of this era generally do not have standardized government crash test ratings like cars. Safety primarily relies on rider skill and proper maintenance.
Braking System:
Front: Drum brake (or disc on later/specific models), Rear: Drum brake. The manual will detail adjustment and maintenance.
Lighting:
Headlight, taillight, brake light, front and rear turn signals. Manual covers bulb replacement and electrical troubleshooting.
Frame Construction:
Steel frame, designed for durability and trail riding.
Protective Gear:
While not part of the manual itself, riders are strongly advised to use helmets, eye protection, gloves, long pants, and sturdy footwear as per industry safety standards.
Infotainment System:
None. This is a utilitarian motorcycle focused on function over advanced electronics.
Driver Assistance Features:
None. Features are purely mechanical and electrical operation.
Connectivity Features:
None. The manual focuses on mechanical and electrical systems, not digital connectivity.
Headlight Type:
Halogen bulb, typically 12V, wattage specified in manual.
Oil Change Interval:
Typically every 4,000 km (2,500 miles) or annually, whichever comes first. Consult the manual for precise intervals and conditions.
Spark Plug Replacement:
Generally around 10,000-12,000 km (6,000-7,500 miles). Manual will specify gap and type (e.g., NGK).
Air Filter Maintenance:
Inspection every 2,000 km (1,250 miles), cleaning/replacement as needed, especially in dusty conditions. Manual specifies cleaning procedure (e.g., washing with soap and water, drying, re-oiling).
Valve Clearance Check:
Typically every 8,000-10,000 km (5,000-6,000 miles). Manual provides detailed procedures and specifications for intake and exhaust valve clearances.
Brake Fluid Type:
DOT 3 or DOT 4 conforming to FMVSS 116. Always use fresh, sealed fluid. Manual will specify exact type and change interval.
Fork Oil Type:
Yamaha's recommended fork oil (e.g., SAE 10W) or a reputable equivalent. Manual specifies type and quantity per fork leg.
Carburetor Clogging:
Common in older carbureted bikes, especially if fuel is left standing. Regular use or fuel stabilizer helps. Manual covers cleaning and tuning.
Fat Tire Wear:
Due to its design, the wide rear tire can wear differently. Proper inflation and avoiding excessive pavement use can prolong life. Manual covers tire inspection and replacement.
Electrical Connections:
Corrosion or loose connections in wiring harnesses can lead to intermittent electrical issues. Manual's wiring diagrams are essential for diagnosis.
Chain And Sprockets:
Regular cleaning, lubrication, and adjustment are critical. Worn sprockets or a stretched chain can affect performance and drivetrain longevity. Manual provides adjustment procedures and wear limits.
Yamaha Legacy:
Yamaha Motor Corporation has a long and esteemed history in motorcycle manufacturing, known for innovation, performance, and reliability across various categories, from sportbikes to cruisers to off-road machines.
Tw200 Development:
The TW200 was developed with a focus on go-anywhere capability, particularly on soft terrain. The adoption of a significantly wider rear tire was a key design choice to improve flotation and traction, giving it its distinctive 'Trailway' moniker and a unique market presence.
Production Span:
The TW200 model range, including the TW200E, saw continuous production from 1987 through 2009, indicating a stable and appreciated design for its intended purpose. Minor updates would have occurred throughout this period.
Manufacturing Origin:
Yamaha motorcycles are typically manufactured in Japan, though assembly may occur in other regions depending on the specific market and model year.
Model Awards:
The TW200 itself is not typically associated with formal 'awards' in the automotive press sense, but it has garnered a strong cult following and recognition among riders for its unique capabilities and reliability, often cited in 'best beginner bikes' or 'most unique bikes' lists.
Reliability Reputation:
Yamaha has a strong reputation for building reliable and durable motorcycles. The TW200, with its simple, air-cooled engine, is generally considered a very robust and low-maintenance machine, provided it is serviced according to the manufacturer's recommendations.
Manual Quality Certification:
The 'professional quality' description implies the manual meets or exceeds the standards expected by certified motorcycle technicians and adheres to industry practices for repair documentation.
