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Yamaha TW200 Series TRAILWAY Complete Workshop Repair Manual 1987-2009

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🏷️ Basic Information Identification Make: Yamaha Model: TW200 TRAILWAY Model Variant: TW200 Series Generation Production Years: 1987-2009 Codes Vin Prefix: 5NW 👋 Introduction Market Position Category: Dual-sport / Trail Motorcycle...
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类型: Motorcycle
厂商:
Yamaha
斯库: 385913
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 Series TRAILWAY Yamaha
Yamaha TW200 Series TRAILWAY Complete Workshop Repair Manual 1987-2009
🏷️ Basic Information
Identification
Make:
Yamaha
Model:
TW200 TRAILWAY
Model Variant:
TW200 Series
Generation
Production Years:
1987-2009
Codes
Vin Prefix:
5NW
👋 Introduction
Market Position
Category:
Dual-sport / Trail Motorcycle
Target Audience:
Enthusiasts seeking reliable, low-maintenance off-road and light street use.
Competitive Analysis
Competitors:
Honda XR series, Kawasaki KLR series, Suzuki DR series.
Differentiation:
Unique fat tire design for exceptional off-road traction and stability.
Key Features
Design Philosophy:
Simplicity, durability, and off-road capability.
User Benefit:
Empowers owners to perform their own maintenance and repairs, saving significant costs.
📋 Manual Details
Coverage Areas
Geographic Coverage:
Global (specifications may vary slightly by region)
Model Coverage:
All Yamaha TW200 TRAILWAY models from 1987 to 2009
Page Count
Estimated Pages:
Over 400
Manual Type
Type:
Complete Workshop Repair Manual / Service Manual
Language
Language:
English
Format
Format:
Digital Download (PDF)
📖 Manual Coverage
Systems Covered
Engine:
Complete engine disassembly, inspection, repair, and reassembly for all variants.
Fuel System:
Carburetor tuning, cleaning, and rebuilding; fuel tank, fuel pump (if applicable), and fuel lines.
Ignition System:
Ignition coil, spark plug, CDI unit, stator, and wiring.
Transmission:
Clutch operation, inspection, and replacement; gearbox disassembly, inspection, and repair.
Chassis Frame:
Frame inspection and repair, suspension (front and rear), steering system.
Brakes:
Front and rear brake system diagnostics, pad replacement, caliper service, and brake fluid bleeding.
Electrical System:
Wiring diagrams, lighting system, battery maintenance, charging system, starter motor.
Wheels Tires:
Tire inspection, replacement, spoke tensioning, wheel bearing service.
Bodywork Trim:
Fender removal and installation, seat service, fuel tank removal and installation, handle bar replacement.
Procedures Included
Maintenance:
Routine maintenance tasks such as oil changes, filter replacements, chain adjustments, valve clearance checks.
Troubleshooting:
Comprehensive diagnostic procedures for identifying and resolving common and uncommon problems.
Repair:
Step-by-step repair instructions for all major and minor components.
Rebuilds:
Complete engine and transmission rebuild procedures.
Assembly Disassembly:
Detailed procedures for taking apart and putting back together all vehicle systems.
Wiring Diagrams:
Complete and detailed electrical wiring schematics for all model years covered.
Technical Depth
Depth Level:
Professional Level: Covers everything from basic maintenance to full engine and transmission rebuilds.
Detail Level:
In-depth with torque specifications, clearances, and measurement data.
Diagnostic Capability:
Advanced diagnostic charts and troubleshooting flowcharts.
📊 Manual Specifications
File Format
Type:
PDF
Searchability:
Fully searchable text for quick information retrieval.
Compatibility:
Compatible with PC, MAC, Tablets, and Smartphones.
Print Quality
Quality:
High-resolution images and diagrams suitable for printing.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Type:
4-stroke, SOHC, 2-valve, air-cooled
Displacement:
197 cc
Bore X Stroke:
66.0 mm x 58.0 mm
Compression Ratio:
9.5:1
Performance
Horsepower:
~16 HP @ 7,500 RPM (approximate, varies by specific year/tuning)
Torque:
~12.5 lb-ft @ 5,500 RPM (approximate, varies by specific year/tuning)
Fuel System
Carburetor Type:
Mikuni VM30 (typically) with Accelerator Pump
Fuel Tank Capacity:
1.8 US gallons (approx. 7 liters)
Lubrication
Oil Type:
Yamalube 4 (or equivalent API SG, SAE 10W-40)
Oil Capacity:
1.70 L (1.80 US qt) / 1.60 L (1.70 US qt) without filter change
🔧 Transmission
Standard
Type:
5-speed constant mesh
Clutch Type:
Wet, multi-disc
Features
Final Drive:
Chain drive
Transmission Oil Type:
Yamalube Gear Oil (or equivalent API GL-4, SAE 80)
Transmission Oil Capacity:
0.55 L (0.58 US qt)
📐 Dimensions
Exterior
Length:
2,055 mm (80.9 in)
Width:
830 mm (32.7 in)
Height:
1,115 mm (43.9 in)
Wheelbase:
1,330 mm (52.4 in)
Ground Clearance:
265 mm (10.4 in)
Weights
Dry Weight:
118 kg (260 lbs)
Wet Weight:
127 kg (280 lbs) (approx.)
Front Tire Size:
180/80-14M/C 77P (Tubeless - distinctive 'fat' tire)
Rear Tire Size:
120/80-18M/C 62P (Tubeless)
Wheelbase Type:
Spoked steel wheels
🛡️ Safety Features
Ratings
Crash Test Ratings:
N/A (Motorcycle)
Active Features
Braking System:
Front: 220 mm disc; Rear: 130 mm drum
Passive Features
Lighting:
Halogen headlight, LED taillight/brake light.
💡 Technology Features
Infotainment
Infotainment System:
N/A (Analog dashboard: speedometer, odometer, neutral indicator, high beam indicator)
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 3,000 km (1,800 miles) or 6 months
Oil Filter Replacement:
Every 2 oil changes or 6,000 km (3,600 miles)
Air Filter Cleaning:
Every 1,000 km (600 miles) or as needed in dusty conditions
Valve Clearance Check:
Every 6,000 km (3,600 miles)
Spark Plug Replacement:
Every 10,000 km (6,000 miles)
Brake Fluid Change:
Every 2 years or 24,000 km (15,000 miles)
Fluid Specifications
Engine Oil Grade:
SAE 10W-40
Engine Oil API Service:
API SG or higher
Brake Fluid Type:
DOT 3 or DOT 4
Known Issues
Common Wear Item:
Carburetor jets can clog if fuel is not fresh or tank is dirty.
Common Wear Item 2:
Fat front tire can require higher tire pressures and may affect steering feel on pavement.
Common Wear Item 3:
Chain and sprockets require regular cleaning and lubrication.
Electrical Component:
Stator output can degrade over time, affecting charging system performance.
📚 Vehicle History
Brand Heritage
Manufacturer Origin:
Japan
Yamaha Motorcycle Legacy:
Yamaha Motor Company is renowned for its innovation and performance across various motorsport disciplines.
Model Evolution
Introduction Year:
1987
Key Updates:
Minor cosmetic updates and slight engine tuning adjustments throughout its production run; generally remained consistent in its core design.
Production
Manufacturing Location:
Japan
Sales Performance:
Consistently popular in off-road and adventure touring communities due to its unique characteristics and reliability.
🏆 Awards & Recognition
Recognitions
Community Recognition:
Highly regarded by adventure riders and trail enthusiasts for its ruggedness and simplicity.
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