🏷️ Basic Information

Make:

Yamaha

Model:

TW200 Trailway

Model Variant:

TW200E

Product Type:

Complete Workshop Service Repair Manual

Model Name Nickname:

Trailway

Covered Years:

1987-2009

Chassis Codes:

N/A (Specific chassis codes for each year are detailed within the manual)

👋 Introduction

Market Position:

The Yamaha TW200 Trailway is a unique dual-sport motorcycle renowned for its ultra-wide rear tire, offering exceptional off-road traction and stability, particularly in soft conditions like sand and mud. It's positioned as a practical, reliable, and accessible machine for recreational trail riding, light commuting, and exploring various terrains.

Competitors:

While not having direct competitors with its specific ultra-wide tire configuration, it competes in the light dual-sport and trail bike segment against models like the Honda CRF230F, Kawasaki KLX230, and sometimes smaller displacement dual-sport bikes depending on intended use.

Key Features:

Ultra-wide 180/80-14 rear tire, air-cooled 4-stroke engine, reliable performance, user-friendly handling, distinctive styling, long-travel suspension, excellent off-road capability in specific conditions.

📋 Manual Details

Systems Covered:

Engine, Transmission, Clutch, Fuel System, Ignition System, Electrical System, Chassis, Suspension, Brakes, Wheels, Tires, Bodywork, Maintenance, Troubleshooting, Diagnostics, Specifications.

Estimated Page Count:

Refer to specific edition details; typically 300-500 pages for a comprehensive workshop manual of this era.

Manual Type:

Workshop Service Repair Manual

Content Focus:

Primarily a repair and service manual, with comprehensive sections on maintenance, troubleshooting, and technical specifications.

Language:

English

Format:

Digital (PDF)

📖 Manual Coverage

Engine:

Detailed disassembly, inspection, repair, and reassembly of all internal engine components including piston, rings, cylinder, crankshaft, connecting rod, camshaft, valves, timing chain, and more. Includes torque specifications and clearance measurements.

Fuel System:

Carburetor (Mikuni VM series) disassembly, cleaning, adjustment, troubleshooting, fuel pump operation, fuel tank and lines.

Transmission Clutch:

Clutch assembly inspection, adjustment, replacement. Transmission disassembly, inspection, repair of gears, shift forks, and drum. Includes lubrication specifications.

Electrical System:

Wiring diagrams, battery, charging system (stator, regulator/rectifier), ignition system (CDI, spark plug), lighting, instrumentation, starter motor, troubleshooting electrical faults.

Suspension Steering:

Front telescopic forks (oil type, seals, damping), rear mono-shock suspension (spring preload, damping), swingarm, steering head bearing maintenance and adjustment.

Brakes:

Front and rear drum brake systems, brake shoe inspection, replacement, adjustment. Hydraulic brake system details (if applicable to later models).

Chassis Frame:

Frame inspection, alignment checks, engine mounting, steering head bearing maintenance.

Maintenance:

Regular scheduled maintenance tasks, oil changes, filter replacements, spark plug checks, air filter cleaning, chain adjustment, brake adjustments, lubrication points.

Troubleshooting:

Step-by-step diagnostic procedures for common problems such as starting issues, poor running, electrical faults, brake performance.

Repair:

Detailed instructions for component disassembly, repair, and reassembly for virtually all parts of the motorcycle.

Specifications:

Comprehensive list of all technical specifications, including torque values, clearances, fluid capacities, electrical resistance values, and more.

Engine Rebuild:

Full engine disassembly, inspection of all internal components, piston and ring replacement, cylinder honing, valve seat grinding, crankshaft balancing and bearing checks, timing chain replacement, gasket and seal replacement.

Carburetor Tuning:

Detailed instructions for jetting adjustments, idle speed settings, and troubleshooting poor fuel atomization or delivery.

Electrical Diagnostics:

Step-by-step fault finding using wiring diagrams, multimeter testing of components like stator, regulator/rectifier, CDI unit, and switches.

Suspension Overhaul:

Front fork seal replacement, oil changes, spring inspection, rear shock absorber function checks.

Wheel Bearing Maintenance:

Inspection, cleaning, lubrication, and replacement of wheel bearings.

Chain Maintenance:

Cleaning, lubrication, adjustment of chain tension, and replacement of drive chain and sprockets.

Depth:

Comprehensive, covering from basic user maintenance to full engine rebuilds and advanced electrical diagnostics. Suitable for both novice mechanics and experienced technicians.

Wiring Diagrams:

Complete, high-resolution wiring diagrams for all electrical systems, color-coded for easy identification.

Special Tools:

Lists required special tools for specific repair procedures, such as fly wheel pullers, seal drivers, and torque wrenches.

📊 Manual Specifications

File Format:

PDF

Searchability:

Text-searchable for quick information retrieval.

Print Quality:

High-resolution, ensuring clarity of text and diagrams.

Binding Type:

N/A (Digital format)

Paper Type:

N/A (Digital format)

⚙️ Engine Specifications

Engine Type:

Air-cooled, 4-stroke, SOHC, 2-valve

Displacement:

196 cc

Bore X Stroke:

67.0 mm x 55.7 mm

Compression Ratio:

9.5:1

Horsepower:

Approximately 14-16 HP (depending on year and specific tuning, exact figures detailed in manual)

Torque:

Approximately 11-13 lb-ft (depending on year and specific tuning, exact figures detailed in manual)

Valve Train:

SOHC, 2 valves

Carburetor:

Mikuni VM26 (or similar specification)

Fuel Tank Capacity:

Approx. 1.8 US gal (7 L)

Fuel Type:

Unleaded gasoline (minimum 87 octane recommended)

🔧 Transmission

Transmission Type:

5-speed constant mesh

Clutch Type:

Wet, multi-plate

Final Drive:

Chain drive

📐 Dimensions

Overall Length:

Approx. 81.5 in (2070 mm)

Overall Width:

Approx. 33.5 in (850 mm) (due to rear tire)

Overall Height:

Approx. 45.5 in (1155 mm)

Wheelbase:

Approx. 51.4 in (1305 mm)

Ground Clearance:

Approx. 6.3 in (160 mm)

Seat Description:

Single, stepped seat for rider and passenger.

Dry Weight:

Approx. 258 lbs (117 kg)

Seat Height:

Approx. 31.5 in (800 mm)

Front Tire:

2.75-21 4PR

Rear Tire:

180/80-14 M/C 4PR (This is the signature feature)

🛡️ Safety Features

Safety Ratings:

N/A (Motorcycle safety ratings are not typically provided in the same manner as passenger vehicles. Focus is on design and component integrity, detailed in manual.)

Brakes:

Front and Rear Drum Brakes. Manual provides detailed adjustment and maintenance procedures for optimal performance.

Lighting:

Headlight, taillight, brake light, turn signals (depending on market regulations). Manual covers bulb replacement and electrical checks.

Frame Construction:

Steel frame and swingarm, designed for durability and trail riding performance.

💡 Technology Features

Infotainment Features:

N/A (Basic instrumentation: speedometer, odometer, high-beam indicator, neutral indicator).

Driver Assistance Features:

N/A (No electronic rider aids beyond standard mechanical operation).

🔧 Maintenance

Oil Change Interval:

Every 3,000 km (1,860 miles) or 6 months, whichever comes first. (Consult manual for exact specifications per year).

Air Filter Cleaning:

Every 1,000 km (620 miles) or 6 months. Replacement as needed.

Spark Plug Check:

Every 3,000 km (1,860 miles).

Engine Oil Type:

Yamalube 4 (or equivalent SAE 10W-40 API SE, SF or SG classification) - Check manual for specific viscosity recommendations based on temperature.

Engine Oil Capacity:

1.40 L (1.5 US qt) with oil filter change; 1.20 L (1.3 US qt) without filter change. (Verify in manual for specific year).

Fork Oil Type:

Yamaha Suspension Oil (or equivalent SAE 10W fork oil) - 390 ml per fork leg.

Brake Fluid Type:

N/A (Drum brakes do not use hydraulic fluid)

Common Issues:

Carburetor clogging due to infrequent use or poor fuel quality, brake shoe wear, occasional electrical connection issues, front fork seal leaks (typical for older bikes with high mileage). The manual provides detailed troubleshooting for these.

📚 Vehicle History

Brand Heritage:

Yamaha Motor Company, established in 1955, has a long and prestigious history in motorcycle manufacturing, known for innovation, performance, and reliability across a wide range of motorcycle types.

Model Evolution:

The TW200 Trailway was introduced to the market in the mid-1980s and has remained largely consistent in its core design and functionality throughout its production run, a testament to its effective and unique concept. Minor updates typically involved emissions controls, graphics, and component refinements.

Production Locations:

Primarily manufactured in Japan.

🏆 Awards & Recognition

Recognitions:

While specific 'awards' might not be readily documented for this utilitarian model, the TW200 is consistently recognized by owners and enthusiasts for its unique capabilities, reliability, and 'go-anywhere' character.