Segment:
Dual-sport motorcycle, known for its off-road capability and user-friendly nature.
Target Audience:
Recreational riders, trail enthusiasts, commuters seeking ruggedness.
Competitors:
Honda TW200 (no direct Honda equivalent, but similar utility/trail bikes like XR series), Kawasaki KLR250, Suzuki DR200S.
Defining Characteristics:
Fat tires for excellent traction and stability on varied terrain, simple and robust air-cooled engine, lightweight and agile.
Model Years Covered:
1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999
Region Coverage:
Primarily North America, with specifications applicable to global variants where applicable.
Estimated Page Count:
300-400 pages (typical for comprehensive service manuals of this era)
Type:
Service Manual / Workshop Manual
Engine:
Engine mechanical, lubrication, cooling, fuel, ignition, emissions control.
Transmission:
Clutch, gearbox operation, internal components, maintenance, and repair.
Chassis:
Frame, suspension (front and rear), steering, wheels, tires.
Brakes:
Front and rear brake systems, hydraulics, servicing, and adjustment.
Electrical:
Battery, charging system, ignition system, lighting, starting system, wiring diagrams, troubleshooting.
Bodywork:
Body panels, fuel tank, seat, fenders, minor adjustments.
Routine Maintenance:
Oil changes, filter replacements, spark plug checks, chain adjustment, lubrication points.
Troubleshooting:
Systematic diagnostic procedures for common and uncommon issues, fault finding charts.
Repair Overhaul:
Detailed step-by-step instructions for component disassembly, repair, reassembly, and adjustment.
Technical Data Specifications:
Torque specifications, clearances, timing, fluid capacities, electrical resistance values.
Depth:
Comprehensive; covers everything from basic rider maintenance to full engine and transmission rebuilds, including electrical diagnostics.
Engine Type:
Four-stroke, SOHC, air-cooled
Engine Displacement:
196 cc
Bore X Stroke:
67.0 mm x 55.7 mm
Horsepower:
Approximately 15-17 hp @ 8000 rpm (estimated, exact figures may vary)
Torque:
Approximately 14-16 Nm @ 6500 rpm (estimated)
Carburetor:
Mikuni VM26 (or similar designation, specific model number may vary)
Fuel Type:
Unleaded gasoline
Fuel Tank Capacity:
7.0 Liters (1.85 US gallons)
Safety Ratings:
N/A (Motorcycles are not rated by organizations like NHTSA or IIHS in the same way as cars).
Braking System:
Front: Disc brake, Rear: Drum brake.
Lighting:
Halogen headlight, taillight, brake light, turn signals.
Engine Oil Change:
Every 3,000 km (1,860 miles) or 6 months, whichever comes first.
Oil Filter Change:
Recommended at every engine oil change.
Spark Plug Inspection:
Every 3,000 km (1,860 miles).
Air Filter Cleaning:
Every 2,000 km (1,240 miles) or more frequently in dusty conditions.
Chain Lubrication Adjustment:
Lubrication: Every 1,000 km (620 miles) or after washing/rain. Adjustment: As needed, check slack regularly.
Engine Oil:
Yamalube 4 (or SAE 20W-40 API SE, SF type service classification oil). Capacity: 1.70 L (1.80 US qt) without filter change, 1.80 L (1.90 US qt) with filter change.
Brake Fluid:
DOT 3 or DOT 4.
Carburetor Issues:
Potential for gumming or blockage if fuel sits for extended periods without stabilizer, leading to hard starting or poor idling. Manual covers cleaning and adjustment.
Clutch Wear:
Can occur with aggressive riding; manual details clutch plate inspection and replacement procedures.
Fatigue In Wide Tires:
While durable, the wide tires can age and develop cracks; manual provides tire inspection guidelines.
Electrical Connections:
Corrosion on connectors can occur over time, affecting lighting or starting; manual details electrical system checks.
Manufacturer:
Yamaha Motor Company is a Japanese manufacturer of motorcycles, marine products, and other motorized products.
Introduction Year:
The TW200 was initially introduced in 1987.
Design Philosophy:
Designed with an emphasis on trail riding and versatility, featuring the distinctive wide tires for enhanced traction and stability.
Production Period:
Original production ran from 1987 to 2001. This manual covers a significant portion of this initial run.
Manufacturing Location:
Japan (typical for Yamaha motorcycles of this era).