Yamaha TW200 TRAILWAY Repair Manual 1987-2009

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🏷️ Basic Information Identification Make: Yamaha Model: TW200 TRAILWAY Model Nickname: Trailway Engine Type: 4-stroke, SOHC, 2-valve, Air-cooled Codes Internal Model Codes: DG07, DG09 (varies by year/region) 👋 Introduction Market...

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类型: Motorcycle

斯库: 294020

标签: 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 Motorcycle Motorcycles Speed Triple Triumph TW200 TRAILWAY Yamaha

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Description

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

TW200 TRAILWAY

Model Nickname:

Trailway

Engine Type:

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

Codes

Internal Model Codes:

DG07, DG09 (varies by year/region)

👋 Introduction

Market Position

Segment:

Dual-sport / Trail Motorcycle

Target Audience:

Riders seeking a reliable, low-maintenance motorcycle for on-road and light off-road use, DIY mechanics, restorers.

Competitive Analysis

Competitors:

Honda XR250L, Kawasaki KLR250, Suzuki DR250S (during its production run).

Key Features

Vehicle Characteristics:

Unique fat rear tire for excellent traction on soft surfaces, simple and robust design, legendary Yamaha reliability.

Manual Value Proposition:

Empowers owners to perform all necessary maintenance and repairs, saving money and extending the life of the motorcycle. Provides access to factory-level technical information.

📋 Manual Details

Coverage Areas

Applicable Model Years:

1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009

Regions Covered:

North America, Europe, Australia (primarily based on common specifications)

Page Count

Estimated Page Count:

300-400

Manual Type

Type:

Factory Service Manual / Workshop Manual

Language

Language:

English

Format

Format:

PDF (Digital Download)

📖 Manual Coverage

Systems Covered

Engine:

Complete engine disassembly, assembly, tuning, diagnostics, lubrication, cooling system, fuel system (carburetor), ignition system, exhaust system.

Transmission:

Gearbox inspection, maintenance, clutch operation, shift mechanism.

Electrical:

Wiring diagrams, lighting system, ignition system components, charging system (stator, regulator/rectifier), battery, starter motor, fuses, switches.

Chassis:

Frame inspection and repair, front suspension (forks), rear suspension (shock absorber, swingarm), steering system, wheels, tires, brakes (front disc, rear drum).

Bodywork:

Fenders, seat, fuel tank, side covers, handlebars, controls, luggage rack (if applicable).

Procedures Included

Maintenance:

Scheduled maintenance, oil changes, filter replacements, spark plug replacement, chain adjustment, brake adjustments, tire pressure checks.

Troubleshooting:

Diagnostic charts for common problems, electrical fault finding, engine performance issues.

Repair:

Step-by-step instructions for component removal, installation, and overhaul (e.g., carburetor rebuild, fork seal replacement).

Specifications:

Torque specifications for critical fasteners, engine timing, valve clearance settings, electrical component specifications.

Technical Depth

Depth:

Comprehensive, covering everything from routine maintenance to complete engine and chassis rebuilds. Includes detailed diagrams and schematics.

📊 Manual Specifications

File Format

File Type:

Searchable:

Printable:

Print Quality

Quality:

High-resolution scans for clear diagrams and text.

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Code:

Engine Displacement:

197 cc

Bore X Stroke:

66.0 mm x 57.0 mm

Compression Ratio:

9.5:1

Valve Configuration:

SOHC, 2 valves

Cooling System:

Air-cooled

Performance

Horsepower:

Approx. 17-19 HP (at the crankshaft, varies by year/tuning)

Torque:

Approx. 11-13 lb-ft (at the crankshaft, varies by year/tuning)

Fuel System

Fuel Delivery:

Carburetor

Carburetor Model:

Mikuni VM30 (or similar 30mm constant velocity carb)

Fuel Type:

Unleaded gasoline (91-93 octane recommended)

Fuel Tank Capacity:

Approx. 2.0 US gallons (7.6 Liters)

🔧 Transmission

Standard

Type:

5-speed constant mesh

Final Drive:

Chain drive

Features

Clutch Type:

Wet, multiple disc

Gear Ratios:

Detailed ratios available in manual (e.g., 1st: 2.833, 2nd: 1.875, 3rd: 1.381, 4th: 1.130, 5th: 0.960 - approximate for common years).

📐 Dimensions

Exterior

Length:

Approx. 81.1 in (2060 mm)

Width:

Approx. 34.6 in (880 mm)

Height:

Approx. 44.1 in (1120 mm)

Wheelbase:

Approx. 52.2 in (1325 mm)

Ground Clearance:

Approx. 10.4 in (265 mm)

Weights

Dry Weight:

Approx. 262 lbs (119 kg)

Wet Weight:

Approx. 282 lbs (128 kg) (with fluids)

Seat Height:

Approx. 32.1 in (815 mm)

Front Tire Size:

2.75-21 4PR

Rear Tire Size:

180/80-14M/C 62P (Wide 'Fat Tire')

🛡️ Safety Features

Ratings

Crash Test Data:

N/A (Motorcycle, not subjected to automotive crash tests).

Active Features

Braking System:

Front: Hydraulic disc, Rear: Drum brake. Manual includes detailed inspection and adjustment procedures.

Lighting:

Headlight, taillight, brake light, turn signals. Manual details wiring and bulb replacement.

Passive Features

Frame Construction:

Steel diamond frame, designed for durability and stability. Manual covers frame inspection for integrity.

💡 Technology Features

Infotainment

Features:

N/A (Basic motorcycle design).

Driver Assistance

Features:

N/A (Basic motorcycle design).

Connectivity

Features:

N/A (Basic motorcycle design).

Instrumentation

Components:

Analog speedometer, odometer, tripmeter, indicator lights for turn signals, neutral, high beam, oil pressure. Manual details their function and diagnostics.

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 2,000-3,000 miles (3,000-5,000 km) or 6 months. Manual provides precise interval and procedure.

Spark Plug Replacement:

Every 6,000-8,000 miles (10,000-12,000 km). Manual specifies correct plug type and gap.

Air Filter Cleaning:

Every 1,000-2,000 miles (1,500-3,000 km) or as needed based on riding conditions. Manual details cleaning and oiling procedure.

Chain Lubrication Adjustment:

Every 500 miles (800 km) or after riding in wet conditions. Manual specifies proper slack and lubrication.

Fluid Specifications

Engine Oil:

Yamalube 4 (or equivalent) SAE 10W-40 API SE, SF, or SG classification, or JASO MA certified oil. Manual specifies capacity.

Brake Fluid:

DOT 3 or DOT 4. Manual details replacement and bleeding procedures.

Fork Oil:

Yamaha 01 or SAE 10W fork oil. Manual specifies viscosity and quantity.

Known Issues

Common Wear Items:

Clutch plates, chain and sprockets, fork seals, rear shock bushings, carburetor O-rings. Manual guides inspection and replacement.

Electrical Components:

Regulator/rectifier failures can occur on older models; manual aids in diagnosis.

Carburetor Performance:

Can become fouled or worn over time, leading to poor running. Manual provides detailed rebuild instructions.

📚 Vehicle History

Brand Heritage

Manufacturer:

Yamaha Motor Corporation, Japan.

Motorcycle Legacy:

Yamaha is renowned for its innovation, performance, and reliability in all types of motorcycles, from sportbikes to off-road and cruisers.

Model Evolution

Introduction Year:

Key Updates:

Minor styling updates, emissions control refinements over the years. Core mechanicals remained largely consistent, highlighting its robust design.

Discontinuation Status:

Discontinued in North America after 2009, though continued in other markets.

Production

Manufacturing Locations:

Primarily Japan.

Sales Niche:

Developed a strong following for its unique capabilities and ease of use, particularly among novice riders and those seeking a versatile trail bike.

🏆 Awards & Recognition

Recognitions

Industry Awards:

N/A (Specific industry awards are not widely documented for this model).

Ratings

Owner Satisfaction:

Consistently high owner satisfaction due to its reliability, ease of use, and distinctive character.

Certifications

Emissions Compliance:

Met prevailing emissions standards for its respective production years in target markets. Manual may contain specific emissions control system details.