Vehicle Segment:
Dual-sport / Dual-purpose motorcycle, known for its off-road capability and unique fat tires
Target Audience:
Riders seeking a rugged, versatile motorcycle for trails, light off-roading, and general utility
Key Competitors:
Honda CTX200, Kawasaki KLR250 (though the TW200 has a more niche appeal due to its tires)
Unique Selling Proposition:
Extremely wide front and rear tires for enhanced traction and stability on soft surfaces (sand, mud, snow)
Design Philosophy:
Simplicity, reliability, and go-anywhere capability in a user-friendly package
Applicable Model Years:
1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999
Estimated Page Count:
300-400 pages (estimated for a comprehensive service manual of this era)
Manual Type:
Factory Service Manual / Repair Manual
Format:
Digital (PDF) or Printed
Engine Service:
Complete engine disassembly, inspection, assembly, valve adjustment, piston/cylinder, crankshaft, camshaft, lubrication system
Fuel System Service:
Carburetor identification, disassembly, cleaning, adjustment, fuel tank, fuel lines, fuel filter
Electrical System Service:
Wiring diagrams, lighting system, ignition system, charging system (stator, rectifier/regulator), starter system, battery service, troubleshooting electrical faults
Drivetrain Service:
Clutch operation and service, transmission disassembly and assembly, final drive (chain and sprockets)
Suspension Service:
Front fork (oil change, seal replacement, spring inspection), rear shock absorber service, swingarm and linkage maintenance
Braking System Service:
Front and rear brake system inspection, adjustment, pad replacement, fluid flush and bleeding
Chassis And Frame Service:
Frame inspection, steering head bearing service, wheel bearing maintenance, general chassis component checks
Bodywork And Trim:
Panel removal and installation, seat service, fender inspection, handlebar and control component service
Maintenance Procedures:
Regular scheduled maintenance, oil changes, filter replacements, lubrication points, chain adjustment, brake adjustments
Troubleshooting Guides:
Diagnostic flowcharts for common starting, running, and electrical issues
Repair Procedures:
Step-by-step instructions for component removal, repair, and reinstallation
Adjustment Procedures:
Carburetor tuning, valve clearance adjustment, brake lever adjustment, clutch lever adjustment
Diagnostic Procedures:
Spark plug inspection, compression testing, ignition timing checks, electrical system voltage/resistance tests
Depth Of Coverage:
Comprehensive, covering routine maintenance to complete engine and chassis overhauls
Diagnostic Capabilities:
Detailed troubleshooting sections for identifying and resolving mechanical and electrical faults
Specifications Data:
Includes all necessary torque specifications, clearances, fluid capacities, and wear limits
Digital Format:
PDF, searchable text for easy navigation
Print Quality:
High-resolution scanned pages, clear legible text and diagrams
Printed Binding:
Coil-bound or saddle-stitched for lay-flat usability (typical for workshop manuals)
Printed Paper Type:
Durable paper stock, often glossy or semi-gloss for image clarity
Engine Type:
Four-stroke, SOHC, 2-valve, Air-cooled
Bore X Stroke:
67.0 mm x 55.7 mm
Horsepower:
Approximately 16-18 HP (Varies slightly by model year and tuning)
Torque:
Approximately 11-13 lb-ft (Varies slightly by model year and tuning)
Carburetor Type:
Mikuni VM26SS (typical for the era, specific model may vary slightly)
Fuel Tank Capacity:
1.6 US gal (6.1 L)
Engine Oil Change:
Every 3,000 km (1,800 miles) or 6 months
Oil Filter Change:
Every 3,000 km (1,800 miles) or 6 months (or as specified in manual)
Valve Adjustment:
Every 6,000 km (3,600 miles) or 12 months
Air Filter Cleaning:
Inspect every 3,000 km (1,800 miles), clean or replace as needed
Spark Plug Replacement:
Inspect every 6,000 km (3,600 miles), replace as needed
Chain Lubrication And Adjustment:
Lubricate every 1,000 km (600 miles), check tension and adjust as needed every 3,000 km (1,800 miles)
Engine Oil Type:
Yamalube 4 (or equivalent SAE 20W-40 API SE, SF, SG type service oil)
Engine Oil Capacity:
1.80 L (1.90 US qt) without filter change; 2.00 L (2.10 US qt) with filter change
Fork Oil Type:
Yamaha Suspension Oil (or equivalent SAE 10W fork oil)
Brake Fluid Type:
DOT 3 (check manual for specific recommendations)
Carburetor Clogging:
Mikuni carburetors can be prone to clogging from stale fuel or debris, requiring periodic cleaning and maintenance.
Stator Failure:
Older stators can degrade over time, affecting charging system performance. Testing and replacement may be necessary.
Tire Wear:
The unique fat tires, while providing excellent traction, can sometimes experience accelerated wear, particularly if ridden aggressively on pavement.
Front Fork Seals:
Front fork seal leaks can occur, necessitating seal replacement and oil service.
Yamaha Motorcycles:
Yamaha Motor Company is a Japanese manufacturer renowned for its high-quality motorcycles, musical instruments, and other motorized products, established in 1955.
Tw200 Introduction:
The TW200 was introduced in 1987 and has seen relatively minor changes over its production run, largely due to its enduring and unique design.
Design Inspiration:
The TW series was inspired by the Yamaha XT200 and designed for specific terrain conditions, notably sandy or soft soil, hence the distinctive fat tires.
Manufacturing Location:
Japan (primarily)
Production Years:
1987 - Present (with the specified manual covering up to 1999)
