Category:
Dual-Sport / Off-Road Motorcycle
Target Audience:
Enthusiasts seeking a reliable, easy-to-maintain, and versatile motorcycle for trails, light off-roading, and urban commuting.
Competitors Era:
Honda XR series, Kawasaki KLR series, Suzuki DR series (smaller displacement variants).
Design Philosophy:
Simple, robust, and user-friendly with a focus on low-end torque and comfortable ergonomics for off-road use.
Unique Selling Points:
Extra-wide tires for superior flotation on soft terrain, user-friendly 4-stroke engine, lightweight and nimble handling.
Engine Systems:
Engine overhaul, cylinder head, piston, crankshaft, oil pump, lubrication system, cooling system (air-cooled specifics).
Fuel System:
Carburetor (VM Series) disassembly, cleaning, adjustment, fuel tank, fuel lines, petcock.
Transmission Drivetrain:
Clutch operation, gear shifting mechanism, transmission disassembly and assembly, final drive (chain and sprockets).
Electrical System:
Ignition system (CDI), lighting system (headlight, taillight, turn signals), battery, charging system (alternator), starter system, wiring diagrams, switchgear.
Suspension Steering:
Front fork (telescopic) inspection, seal replacement, oil levels, rear shock absorber adjustments and replacement, steering head bearing service.
Braking System:
Front disc brake system maintenance, caliper overhaul, brake pad replacement, hydraulic lines, rear drum brake adjustment and service.
Chassis Bodywork:
Frame inspection, footpegs, handlebars, seat, fenders, exhaust system removal and installation.
Routine Maintenance:
Oil changes, filter replacement, spark plug checks, chain lubrication and adjustment, tire pressure checks, brake adjustments.
Troubleshooting:
Diagnostic charts for common starting issues, running problems, electrical faults, and performance degradation.
Repair Rebuild:
Complete engine disassembly, inspection, and reassembly procedures; carburetor rebuilding; suspension component overhauls; brake caliper rebuilding.
Electrical Diagnostics:
Wiring diagram interpretation, testing ignition components, charging system diagnostics, troubleshooting lighting circuits.
Depth:
Comprehensive, covering everything from basic owner maintenance to full engine rebuilds and advanced diagnostics.
Engine Type:
Air-cooled, 4-stroke, SOHC, 2-valve
Bore X Stroke:
66.0 mm x 57.0 mm
Carburetor:
Mikuni VM26SS (single)
Ignition System:
CDI (Capacitor Discharge Ignition)
Starting System:
Kickstart
Horsepower:
Approximately 15-17 HP (estimated, varies by specific year and tuning)
Torque:
Approximately 10-12 lb-ft (estimated)
Fuel Tank Capacity:
Approximately 1.6 gallons (6.1 L)
Fuel Type:
Unleaded gasoline (87 octane recommended)
Length:
Approximately 80.7 inches (2050 mm)
Width:
Approximately 34.1 inches (865 mm)
Height:
Approximately 44.5 inches (1130 mm)
Wheelbase:
Approximately 51.2 inches (1300 mm)
Dry Weight:
Approximately 258 lbs (117 kg)
Wet Weight:
Approximately 275 lbs (125 kg) (estimated)
Front Tire Size:
130/80-18M/C 63P
Rear Tire Size:
180/80-14M/C 61P
Wheel Type:
Spoked wheels
Wheelbase Notes:
Crucial for stability in off-road conditions.
Safety Standard:
Industry standard for motorcycles of its era; no formal crash ratings like cars.
Braking Performance:
Front disc brake provides adequate stopping power; rear drum brake offers modulation.
Suspension Stability:
Long-travel suspension aids in absorbing bumps and maintaining tire contact on uneven terrain.
Chassis Design:
Steel frame provides a robust foundation.
Lighting:
Halogen headlight for improved night visibility.
Oil Change Interval:
Every 3,000 km (1,800 miles) or 6 months, whichever comes first.
Spark Plug Check:
Every 6,000 km (3,600 miles)
Valve Clearance Check:
Every 12,000 km (7,200 miles) or 12 months
Air Filter Cleaning:
Every 3,000 km (1,800 miles) or more frequently in dusty conditions.
Engine Oil Type:
Yamalube 4 (or equivalent) SAE 10W-30 or 10W-40 API SE, SF, or SG classification.
Engine Oil Capacity:
1.50 L (1.6 US qt, 1.3 Imp qt) without filter change; 1.70 L (1.8 US qt, 1.5 Imp qt) with filter change.
Fork Oil Type:
Yamaha Fork Oil G-10 or equivalent SAE 10W fork oil.
Fork Oil Capacity:
Approximately 213 ml (7.2 US oz) per fork leg.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Common Wear Items:
Clutch plates, brake pads, steering head bearings, wheel bearings, and the wide tires are prone to wear due to their intended use.
Carburetor Tuning:
Carburetors can require periodic cleaning and adjustment to maintain optimal performance, especially when subjected to varied altitudes or fuel quality.
Electrical Connections:
Older wiring harnesses and switchgear can develop corrosion or wear, leading to intermittent electrical issues, which this manual will help diagnose.
Manufacturer Focus:
Yamaha is renowned for its high-performance motorcycles, musical instruments, and audio equipment, with a strong heritage in motorsports.
Tw Series Lineage:
The TW200 is part of Yamaha's dual-purpose line, known for its distinctive wide tires, originating from the early 1980s TW125 and evolving into the popular TW200.
Original Production Start:
Early 1980s (TW125 introduced earlier, TW200 refined thereafter)
Manufacturing Location:
Primarily Japan
Model Longevity:
The TW200 platform has proven to be remarkably enduring, with production continuing for many years, demonstrating its successful design.
