🏷️ Basic Information

Make:

Yamaha

Model:

TW200 Trailway

Model Nickname:

Trailway

Body Style:

Dual-Sport Motorcycle

Production Years:

1987-2009

Chassis Codes:

Commonly identified by frame VIN sequences, specific codes vary by year.

👋 Introduction

Target Audience:

Owners, mechanics, and enthusiasts seeking to perform maintenance, repairs, and troubleshooting on Yamaha TW200 Trailway motorcycles.

Value Proposition:

Provides access to factory-level information, enabling cost-effective maintenance and ensuring correct repair procedures.

Alternatives:

Other aftermarket repair manuals (e.g., Haynes, Clymer) may exist, but factory manuals offer the most authoritative and complete information.

No Expiry:

License is perpetual, no subscription or expiry dates.

Instant Access:

Available for immediate download to various devices.

Completeness:

Covers the entire production span of the TW200 Trailway from 1987 to 2009.

📋 Manual Details

Primary Coverage:

Full service, repair, maintenance, troubleshooting, diagnostics, and overhaul for Yamaha TW200 Trailway motorcycles.

Geographic Scope:

Typically covers specifications and procedures relevant to global markets, with a strong focus on North American and European specifications if applicable to the original manual's origin.

Estimated Pages:

Hundreds (exact number varies by specific edition, but comprehensive factory manuals are typically 300+ pages).

Type:

Factory Service and Repair Workshop Manual

Language:

English

Format:

Digital Download (PDF)

📖 Manual Coverage

Engine:

Complete engine disassembly, assembly, tuning, lubrication, cooling system, valve clearance adjustment, piston and cylinder inspection, crankshaft and connecting rod service.

Fuel System:

Carburetor disassembly, cleaning, adjustment, fuel pump, fuel lines, fuel tank servicing.

Transmission:

Gearbox disassembly, inspection, lubrication, clutch operation, shifting mechanism.

Drivetrain:

Final drive chain and sprockets, lubrication, adjustment, replacement.

Suspension:

Front telescopic forks (oil change, seal replacement, spring inspection), rear monoshock or twin shock absorber (rebuild, adjustment), linkage systems.

Brakes:

Front and rear brake system servicing, hydraulic system (master cylinder, caliper, brake lines, brake fluid flush), drum brake maintenance, brake pad/shoe replacement, bleeding procedures.

Electrical System:

Ignition system (spark plug, CDI unit, coil), charging system (stator, rectifier/regulator), starting system (starter motor, battery), lighting system (headlight, taillight, turn signals), wiring diagrams, troubleshooting electrical faults.

Frame And Bodywork:

Frame inspection, front fork assembly, handlebars, seat, fenders, exhaust system, and other body components.

Wheels And Tires:

Wheel bearing maintenance, tire replacement, spoke tensioning, wheel balancing.

Maintenance:

Scheduled maintenance checks, oil changes, filter replacements, chain lubrication and adjustment, brake checks, tire pressure checks.

Troubleshooting:

Diagnostic flowcharts for common problems, identifying causes and solutions for performance issues, electrical faults, starting problems, etc.

Repair:

Step-by-step instructions for component replacement, assembly, and disassembly of all major systems.

Overhaul:

Complete engine rebuild procedures, including detailed specifications for critical components.

Specifications:

Torque values, clearance measurements, fluid capacities, electrical resistance values, and other critical technical data.

Depth:

Comprehensive, covering everything from basic routine maintenance to complete engine and component rebuilds. Suitable for professional technicians and experienced DIY mechanics.

📊 Manual Specifications

File Type:

PDF (Portable Document Format)

Searchability:

Typically text-searchable, allowing for quick location of specific information.

Resolution:

High-resolution scans of original factory manuals, ensuring clear diagrams and text.

Scalability:

Scalable for printing on standard paper sizes.

Binding:

N/A (Digital Download)

Paper:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Type:

Four-stroke, SOHC, air-cooled

Displacement:

196 cc (Cubic Centimeters)

Bore X Stroke:

67.0 mm x 55.7 mm (approximate, check manual for precise figures per year)

Compression Ratio:

9.5:1 (typical, confirm with manual)

Valve Train:

SOHC, 2 valves per cylinder

Horsepower:

Approximately 16-18 HP (Horsepower) at peak RPM (specific figures vary by year and tuning).

Torque:

Approximately 14-15 Nm (Newton-meters) at peak RPM (specific figures vary by year and tuning).

Carburetor:

Mikuni VM Series (e.g., VM26 or similar, check manual for exact model and jetting).

Fuel Type:

Unleaded gasoline, minimum 87 octane (check manual for specific octane recommendations).

🔧 Transmission

Type:

Constant mesh, 5-speed sequential manual transmission

Clutch:

Wet, multiple disc

Final Drive:

Chain drive (RK 520 or similar, check manual for specific pitch and link count)

Gear Ratios:

Specific gear ratios are detailed within the manual, critical for understanding performance characteristics.

📐 Dimensions

Overall Length:

Approx. 2120 mm (83.5 in)

Overall Width:

Approx. 820 mm (32.3 in)

Overall Height:

Approx. 1115 mm (43.9 in)

Seat Height:

Approx. 775 mm (30.5 in)

Ground Clearance:

Approx. 265 mm (10.4 in)

Dry Weight:

Approx. 127 kg (280 lbs)

Fuel Capacity:

Approx. 7.0 liters (1.8 US gal)

Oil Capacity:

Approx. 1.1 liters (0.29 US gal) without filter change, 1.2 liters (0.32 US gal) with filter change (verify with manual).

🛡️ Safety Features

Safety Standards:

Designed to meet relevant motorcycle safety standards for its production era. Specific crash test ratings are not typically published for this class of motorcycle.

Braking System:

Disc brake front, Drum brake rear (earlier models may have drum front as well, manual will clarify).

Lighting:

Headlight, taillight, brake light, turn signals.

Frame Construction:

Steel tube frame for rigidity and durability.

💡 Technology Features

Features:

Basic motorcycle instrumentation: speedometer, odometer, neutral indicator, high beam indicator. No modern infotainment systems are present.

Features:

None. This is a mechanically operated motorcycle.

Features:

No electronic connectivity features.

🔧 Maintenance

Engine Oil Change:

Every 3,000 km (1,800 miles) or 6 months (check manual for precise interval).

Oil Filter Replacement:

Every engine oil change (if applicable, some models may use a screen).

Air Filter Cleaning Replacement:

Inspect every 3,000 km (1,800 miles), clean or replace as needed, especially in dusty conditions.

Spark Plug Replacement:

Typically every 10,000 km (6,000 miles) or as recommended by the manual.

Valve Clearance Check:

Every 6,000 km (3,600 miles) or annually.

Brake Fluid Flush:

Every 2 years or as per manual recommendation, critical for hydraulic brake system performance.

Engine Oil Viscosity:

Yamalube 4 (or equivalent) SAE 10W-40 API SG or higher (verify with manual for exact specifications).

Brake Fluid Type:

DOT 3 or DOT 4 hydraulic brake fluid (check manual for specific type).

Fork Oil Type Volume:

Yamaha Fork Oil (or equivalent) SAE 10W, 488 ml per fork leg (verify with manual for exact type and quantity).

Common Wear Items:

Clutch plates, brake pads/shoes, tires (due to unique design and usage), swingarm bushings, fork seals.

Carburetor Performance:

Carburetor can become clogged over time, requiring cleaning and adjustment. Jetting may need to be adapted for altitude or modifications.

Electrical Connections:

Corrosion or loose connections in the wiring harness can cause intermittent electrical faults, especially in humid environments.

📚 Vehicle History

Manufacturer:

Yamaha Motor Company, known for innovation and quality in motorcycles and other powered vehicles.

Development Focus:

Designed as a lightweight, user-friendly dual-sport motorcycle capable of handling both on-road commuting and off-road trail riding, distinguished by its iconic fat tires.

Key Design Elements:

The signature oversized front and rear tires (often 130/80-18 front and 180/80-14 rear) provide excellent traction and a unique aesthetic, contributing to its trail-riding prowess.

Manufacturing Location:

Primarily Japan (specific plant may vary).

🏆 Awards & Recognition

Market Reputation:

Highly regarded for its durability, simplicity, and off-road capability. Cult following among riders who appreciate its unique character and 'go-anywhere' versatility.