🏷️ Basic Information

Make:

Yamaha

Model:

TRAILWAY TW200

Vehicle Years Covered:

1987-1999

Specific Manual Year:

1991

Model Code Common:

TW200

👋 Introduction

Segment:

Dual-sport / Trail motorcycle

Target Audience:

Off-road enthusiasts, casual riders, urban commuters seeking rugged reliability

Key Competitors:

Honda CRF230F, Kawasaki KL250-A1 Super Sherpa, Suzuki DR200SE

Vehicle Unique Selling Points:

Fat tire design for superior traction and stability on soft terrain, legendary Yamaha reliability, simple and robust engineering

📋 Manual Details

Primary Coverage:

Comprehensive repair and maintenance for the Yamaha TRAILWAY TW200

Included Years:

1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999

Estimated Pages:

300-400

Type:

Service Manual / Repair Manual

Language:

English

Format:

Printed Manual

📖 Manual Coverage

Engine Mechanical:

Complete overhaul procedures, piston, rings, cylinder, valve train, camshaft, crankshaft, lubrication system

Fuel System:

Carburetor disassembly, cleaning, adjustment, jetting, fuel tank, fuel lines, petcock

Electrical System:

Ignition system, stator, CDI unit, spark plug, wiring diagrams, lighting, charging system, battery

Transmission:

Clutch operation, gear shifting mechanism, transmission disassembly and reassembly

Suspension:

Front fork disassembly, seal replacement, oil levels, rear shock absorber service

Brakes:

Front and rear brake system service, pad replacement, caliper inspection, brake fluid replacement

Chassis And Bodywork:

Frame inspection, seat removal, fender service, handlebar replacement

Routine Maintenance:

Oil changes, filter replacements, spark plug checks, chain lubrication and adjustment, air filter cleaning

Troubleshooting:

Diagnostic charts for common starting, running, and electrical issues

Repair Procedures:

Step-by-step guides for component disassembly, repair, and reassembly

Technical Specifications:

Detailed torque values, clearances, fluid capacities, and adjustment specifications

Depth:

Full mechanical and electrical overhaul, advanced diagnostics, component-level repair

📊 Manual Specifications

Digital Quality:

N/A (Printed Manual)

Print Resolution:

High-quality, clear text and diagrams

Binding:

Professional binding for durability (e.g., comb binding, saddle stitch)

Paper Quality:

Durable, easy-to-clean paper stock suitable for workshop environments

⚙️ Engine Specifications

Engine Type:

Four-stroke, SOHC, air-cooled

Displacement:

197cc

Bore X Stroke:

67.0 mm x 55.7 mm

Compression Ratio:

9.5:1

Horsepower Est:

15-18 HP @ 7500 RPM (estimated)

Torque Est:

11-13 lb-ft @ 6000 RPM (estimated)

Carburetor Type:

Mikuni VM26 (single)

Fuel Type:

Unleaded gasoline

🔧 Transmission

Transmission Type:

5-speed constant mesh

Clutch Type:

Wet, multi-plate

Final Drive:

Chain drive

📐 Dimensions

Length:

2,015 mm (79.3 in)

Width:

815 mm (32.1 in)

Height:

1,115 mm (43.9 in)

Wheelbase:

1,330 mm (52.4 in)

Ground Clearance:

255 mm (10.0 in)

Dry Weight:

116 kg (256 lbs)

Fuel Capacity:

7.0 L (1.8 US gal)

Front Tire Size:

130/80-18M/C 63P

Rear Tire Size:

180/80-14M/C 62P

Wheel Type:

Spoked

🛡️ Safety Features

Safety Certification:

N/A (Motorcycle)

Braking System:

Hydraulic front disc brake, mechanical rear drum brake

Lighting:

Halogen headlamp, taillight, brake light, turn signals

💡 Technology Features

Infotainment System:

N/A (Basic motorcycle instrumentation)

Assistance Features:

N/A (Mechanical systems)

🔧 Maintenance

Engine Oil Change:

Every 1,500 km (930 miles) or 6 months, whichever comes first

Air Filter Cleaning:

Every 500 km (310 miles) or as needed in dusty conditions

Spark Plug Replacement:

Every 5,000 km (3,100 miles)

Valve Clearance Check:

Every 10,000 km (6,200 miles)

Engine Oil Type:

Yamaha Genuine Oil API SG, SAE 10W-40 or 20W-40

Engine Oil Capacity:

1.4 L (1.5 US qt) without filter change, 1.5 L (1.6 US qt) with filter change

Brake Fluid Type:

DOT 3

Common Wear Items:

Tires (especially the unique rear tire), brake pads, chain and sprockets, carburetor jets can clog with age/infrequent use.

Electrical Notes:

Check stator output and CDI unit for reliability issues, especially on higher mileage examples.

📚 Vehicle History

Yamaha Motorcycles:

Yamaha Motor Company, established in 1955, renowned for innovation, performance, and durability across various motorsport disciplines.

Tw200 Lineage:

The TW200 has been a consistent performer in Yamaha's lineup, celebrated for its unique fat tire design and go-anywhere capability. The core design remained largely consistent through the 1987-1999 period, with minor updates.

Manufacturing Location:

Japan

🏆 Awards & Recognition

Industry Accolades:

While not typically winning 'awards' in the traditional sense, the TW200 has garnered a strong cult following and is recognized for its class-leading off-road capability and longevity.