Market Position Vehicle:
The Yamaha TW200 Trailway is a dual-sport motorcycle renowned for its exceptional off-road capability, particularly in soft terrain like sand and mud, due to its characteristically wide tires. It occupies a niche as a reliable, go-anywhere utility bike with a simple, durable design.
Competitive Analysis Vehicle:
Competes with other small-displacement dual-sport and trail bikes, but its unique wide-tire design sets it apart, offering superior flotation in challenging off-road conditions where conventional bikes might struggle.
Key Features Vehicle:
Iconic ultra-wide 'balloon' tires for exceptional traction and flotation, torquey single-cylinder engine, simple and robust construction, lightweight for its class, reliable off-road performance, comfortable seating for extended rides.
Model Years Covered:
1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999
Estimated Page Count:
Approximately 250-350 pages (typical for a comprehensive service manual of this era)
Manual Type:
Factory Service Manual / Repair Manual
Format:
Likely Printed Booklet (original), PDF Digital Download (common for aftermarket sales)
Engine Systems:
Engine overhaul, carburetor tuning, ignition system, valve adjustment, cooling system (if applicable, though typically air-cooled), lubrication system, exhaust system.
Transmission Drivetrain:
Clutch operation, gearbox disassembly and assembly, final drive maintenance (chain/sprockets), lubrication.
Chassis Suspension:
Front fork service and adjustment, rear shock absorber service, swingarm maintenance, wheel bearing inspection and replacement, steering head bearing service.
Braking System:
Front and rear brake pad replacement, brake caliper service, brake fluid flush and bleeding, master cylinder inspection.
Electrical System:
Wiring diagrams, lighting system (headlight, taillight, turn signals), battery maintenance, charging system (stator, rectifier/regulator), ignition coil testing, fuse replacement.
Fuel System:
Fuel tank inspection, fuel filter replacement, carburetor disassembly, cleaning, and reassembly, fuel lines.
Bodywork Cosmetics:
Fairing removal and installation, seat maintenance, fender repair/replacement, decal application.
Maintenance Procedures:
Oil changes, filter replacements, chain lubrication and adjustment, spark plug replacement, air filter cleaning/replacement, brake fluid checks, tire pressure checks.
Troubleshooting Guides:
Diagnostic charts for common starting issues, running problems, electrical faults, and performance degradation.
Repair Procedures:
Step-by-step instructions for engine rebuilds, transmission repairs, suspension overhauls, electrical component replacement, and body panel repairs.
Special Tools:
Identification of specialized tools required for specific maintenance and repair tasks (e.g., torque wrenches, valve adjustment tools, clutch holding tools).
Wiring Diagrams:
Detailed electrical system wiring diagrams with component identification and color codes.
Technical Depth:
Comprehensive from basic owner maintenance to full engine and transmission rebuilds, including detailed torque specifications, clearances, and assembly sequences.
Manual Type Clarification
Manual Type Clarification:
This manual is a comprehensive factory service manual, providing detailed instructions, diagrams, and specifications for all aspects of the vehicle's maintenance, repair, and troubleshooting. It is designed for both professional technicians and knowledgeable DIY enthusiasts.
Engine Type:
Air-cooled, four-stroke, SOHC, single-cylinder
Displacement:
196 cc (12.0 cu in)
Bore X Stroke:
67.0 mm x 55.7 mm (2.64 in x 2.19 in)
Horsepower:
Approximately 16-18 hp @ 7,000 rpm (typical for this engine configuration)
Torque:
Approximately 11-13 lb-ft @ 5,500 rpm (typical)
Carburetor Type:
Mikuni VM Series (e.g., VM26 or similar downdraft type)
Fuel Delivery:
Carburetor with diaphragm pump
Fuel Type:
Unleaded gasoline
Oil Capacity:
Approximately 1.4 L (1.5 US qt)
Cooling System Type:
Air-cooled
Overall Length:
Approx. 2,010 mm (79.1 in)
Overall Width:
Approx. 830 mm (32.7 in) (including handlebars)
Overall Height:
Approx. 1,115 mm (43.9 in)
Wheelbase:
Approx. 1,330 mm (52.4 in)
Ground Clearance:
Approx. 260 mm (10.2 in)
Seat Height:
Approx. 805 mm (31.7 in)
Curb Weight:
Approx. 118 kg (260 lbs)
Fuel Capacity:
Approx. 6.5 L (1.7 US gal)
Payload Capacity:
Not officially specified, but designed for single rider with light luggage.
Front Tire Size:
130/80-18 (Note: 'Balloon' tire)
Rear Tire Size:
180/80-14 (Note: 'Balloon' tire)
Front Suspension Travel:
Approx. 156 mm (6.1 in)
Rear Suspension Travel:
Approx. 150 mm (5.9 in)
Safety Ratings:
Motorcycles of this era are not typically subjected to formal crash testing like automobiles. Safety is derived from design, handling, and rider adherence to safe practices.
Active Safety Features:
Responsive braking system, predictable handling, wide tires for stability in varied conditions.
Passive Safety Features:
Durable frame construction, protective rider gear is essential.
Oil Change Interval:
Every 3,000 km (2,000 miles) or 6 months, whichever comes first.
Air Filter Maintenance:
Clean every 3,000 km (2,000 miles), replace as needed.
Spark Plug Replacement:
Inspect every 6,000 km (4,000 miles), replace as needed.
Valve Adjustment Interval:
Every 10,000 km (6,000 miles) or as per manual recommendation for intake and exhaust clearances.
Brake Fluid Flush:
Every 2 years or as per manual recommendation.
Engine Oil Type:
Yamalube 4 (or equivalent) SAE 10W-40 API SG or higher, or SAE 20W-50 API SG or higher in warmer climates. Consult manual for exact API service classification.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid.
Final Drive Oil:
While the TW200 uses a chain drive, the primary lubrication is via chain lube. The gearbox typically uses the same engine oil.
Clutch Fluid Type:
Not applicable, uses engine oil lubrication.
Common Issues:
Carburetor gumming if left with fuel for extended periods, weak spark plug cap connection, normal wear on wide tires, potential for carb slide needle wear affecting jetting.
Maintenance Tips:
Regular chain maintenance is crucial. Thorough cleaning and lubrication will extend its life. Proper storage with fuel stabilizer is recommended for periods of non-use.
Brand Heritage:
Yamaha Motor Company, established in 1955, has a rich history in motorcycle manufacturing, known for innovation, performance, and reliability across various disciplines, from racing to recreational riding.
Model Evolution:
The TW200 was introduced in 1987 and has remained remarkably consistent in its core design, a testament to its success and suitability for its intended purpose. Minor updates typically involved graphics, color schemes, and potentially emissions-related refinements over the years. The manual's coverage from 1987 to 1999 encompasses the initial and highly successful period of the model's life.
Production Period:
The TW200 has been in continuous production since 1987, with the years 1987-1999 representing its formative and highly popular era.
