🏷️ Basic Information

Make:

Yamaha

Model:

TW200 TRAILWAY

Model Nickname:

TW200

Vehicle Type:

Dual-sport Motorcycle

Production Years Covered:

1987-2009

Engine Code General:

200cc air-cooled four-stroke SOHC

👋 Introduction

Niche:

Iconic, go-anywhere dual-sport motorcycle known for its torquey engine and exceptionally wide rear tire, appealing to riders seeking off-road capability and utilitarian practicality.

Competitors:

Honda CRF230F, Kawasaki KLR250 (older models), Suzuki DR200SE. The TW200 stands out with its unique fat rear tire and low-seat height.

Defining Feature 1:

Ultra-wide 180/80-14 rear tire for exceptional traction and stability on soft terrain.

Defining Feature 2:

Torquey, reliable 196cc air-cooled engine, easy to manage power delivery.

Defining Feature 3:

Low seat height and overall manageable size for accessibility.

Purpose:

Ideal for trail riding, light off-roading, commuting, and utility tasks.

📋 Manual Details

Primary Coverage:

All models and all repairs A-Z for Yamaha TW200 TRAILWAY (1987-2009)

Secondary Coverage:

Model-specific technician-level repair information

Estimated Page Count:

Likely 300-600+ pages (typical for comprehensive service manuals)

Type:

Service Repair Workshop Manual

Source Type:

Dealer/Technician level

Language:

English

Format:

Digital (likely PDF)

File Type Details:

Searchable, printable PDF

📖 Manual Coverage

Engine:

Complete overhaul, troubleshooting, tuning, cooling system, lubrication, valve clearance, piston, rings, cylinder, camshaft, crankshaft, ignition system, fuel system.

Transmission:

Clutch operation, gearbox assembly, gear selection, maintenance, repair, lubrication, troubleshooting.

Drivetrain:

Final drive (chain and sprockets), maintenance, inspection, replacement.

Suspension:

Front fork (telescopic) disassembly, inspection, service, oil changes, seal replacement. Rear shock absorber inspection, adjustment, and replacement. Swingarm and linkage maintenance.

Brakes:

Front and rear brake systems (likely drum or disc depending on specific year/market variant), hydraulic components, bleeding procedures, pad/shoe replacement, caliper/master cylinder service.

Electrical:

Wiring diagrams, battery, charging system (stator, rectifier/regulator), ignition system components (CDI, coil, spark plug), lighting (headlight, taillight, indicators), starting system (starter motor, solenoid), instrumentation, fuses, relays, troubleshooting electrical faults.

Fuel System:

Carburetor disassembly, cleaning, adjustment, jetting, fuel tank, fuel lines, petcock, fuel filter replacement.

Exhaust System:

Muffler, header pipe, gasket replacement, inspection.

Frame And Bodywork:

Frame inspection, steering head bearing service, body panel removal/installation, seat, fenders, handlebars, controls.

Wheels And Tires:

Spoke wheel maintenance, tire replacement, rim repair, balancing, wheel bearing service.

Routine Maintenance:

Oil changes, filter replacement, chain lubrication and adjustment, air filter cleaning/replacement, spark plug replacement, brake adjustment, lubrication points.

Troubleshooting:

Diagnostic procedures for common and uncommon issues across all systems, symptom-based troubleshooting guides.

Repair Procedures:

Step-by-step instructions for component removal, disassembly, inspection, repair, reassembly, and installation.

Disassembly Reassembly:

Detailed guidance on taking apart and putting back together major vehicle components and sub-assemblies.

Technical Specifications:

Torque values, clearances, fluid types and capacities, electrical resistance values, diagnostic parameters.

Wiring Diagrams:

Comprehensive electrical schematics for all model years and configurations.

Depth:

Comprehensive: Covers everything from basic maintenance and checks to complete engine and transmission rebuilds, advanced electrical diagnostics, and frame repairs.

User Level:

Suitable for DIY mechanics and professional technicians alike.

📊 Manual Specifications

Digital Format:

PDF

Searchability:

Searchable text content

Printability:

Printable pages

Image Resolution:

High-resolution illustrations and diagrams

Binding:

N/A (Digital Format)

Paper:

N/A (Digital Format)

⚙️ Engine Specifications

Engine Type:

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

Displacement:

196 cc

Bore X Stroke:

67.0 mm x 55.7 mm (typical, verify with specific model year)

Compression Ratio:

9.5:1 (typical, verify with specific model year)

Starting System:

Electric starter and kick starter

Ignition:

CDI (Capacitor Discharge Ignition)

Horsepower:

~16-17 HP @ 7500 RPM (estimated, varies by year and tuning)

Torque:

~15-16 Nm @ 6000 RPM (estimated, varies by year and tuning)

Fuel Delivery:

Carburetor (e.g., Mikuni VM26)

Fuel Tank Capacity:

6.0 L (1.6 gal) (typical)

Oil Type:

Yamaha Genuine Yamalube or API SE, SF, SG or SH, JASO MA classified SAE 10W-30 or 20W-40

Oil Capacity With Filter:

1.6 L (1.7 US qt) (typical, verify)

Oil Filter Type:

Cartridge type (e.g., Yamaha part # 4X7-13440-90-00)

🔧 Transmission

Transmission Type:

Constant mesh 5-speed

Clutch:

Wet, multiple disc

Gear Ratios:

Refer to manual for specific ratios per gear. Designed for versatile riding.

Final Drive:

Chain drive (e.g., 520 O-ring chain)

Transmission Oil Type:

Yamaha Genuine Gear Oil or equivalent SAE 80 API GL-4

Transmission Oil Capacity:

0.7 L (0.7 US qt) (typical, verify)

📐 Dimensions

Overall Length:

2010 mm (79.1 in) (typical)

Overall Width:

820 mm (32.3 in) (typical)

Overall Height:

1120 mm (44.1 in) (typical)

Seat Height:

770 mm (30.3 in) (typical)

Wheelbase:

1315 mm (51.8 in) (typical)

Ground Clearance:

255 mm (10.0 in) (typical)

Dry Weight:

~127 kg (280 lbs) (typical)

Wet Weight:

~134 kg (295 lbs) (typical, with fluids)

Front Tire:

2.75-21 4PR

Rear Tire:

180/80-14M/C 7PR

Front Wheel Size:

21 inches

Rear Wheel Size:

14 inches

Front Suspension Type:

Telescopic fork

Front Suspension Travel:

170 mm (6.7 in) (typical)

Rear Suspension Type:

Swingarm, Monoshock (or Twin shocks on some early models, manual will clarify)

Rear Suspension Travel:

156 mm (6.1 in) (typical)

🛡️ Safety Features

Safety Certification:

Meets applicable DOT/EPA standards for motorcycles. Specific crash ratings not typically applied to this class of off-road/dual-sport.

Braking System:

Front: Drum or Disc (model dependent), Rear: Drum

Lighting:

Halogen headlight, taillight, brake light, front and rear turn signals.

Chassis Design:

Steel frame, integrated rider controls.

💡 Technology Features

Features:

Basic instrumentation including speedometer, odometer, and indicator lights. No advanced infotainment systems.

Features:

None. Focus is on mechanical simplicity and off-road capability.

Features:

None.

System:

Carburetor-based fuel and ignition timing control. CDI system is relatively simple and robust.

🔧 Maintenance

Engine Oil Change:

Every 3,000 km (1,860 miles) or 6 months, whichever comes first (typical, refer to manual for precise intervals).

Air Filter Cleaning:

Every 1,000 km (620 miles) or 6 months (typical, depending on operating conditions).

Spark Plug Replacement:

Every 6,000 km (3,700 miles) or 12 months (typical).

Valve Clearance Check:

Every 6,000 km (3,700 miles) or 12 months (typical).

Chain Lubrication Adjustment:

Every 1,000 km (620 miles) (typical).

Engine Oil:

Yamaha Genuine Yamalube or API SE, SF, SG or SH, JASO MA classified SAE 10W-30 or 20W-40

Transmission Oil:

Yamaha Genuine Gear Oil or equivalent SAE 80 API GL-4

Fork Oil:

Yamaha Genuine Fork Oil or equivalent SAE 10W (typical)

Brake Fluid:

DOT 3 or DOT 4 (if applicable, typically for disc brake models)

Common Wear Items:

Tires (especially rear due to width and use), brake pads/shoes, chain and sprockets, spark plug, air filter.

Carburetor Issues:

Can become clogged with debris if fuel is not clean or if the bike sits for extended periods. May require periodic cleaning and adjustment.

Electrical Connections:

As with many older bikes, corrosion on electrical connectors can lead to intermittent issues. Manual provides troubleshooting for this.

Suspension Seals:

Front fork seals can leak over time, requiring replacement. Manual details this procedure.

📚 Vehicle History

Manufacturer:

Yamaha Motor Corporation is a Japanese company known for its wide range of products, including motorcycles, marine products, and musical instruments. Yamaha motorcycles are renowned for their reliability and innovation.

Introduction Year:

1985

Key Changes 1987-2009:

Minor cosmetic updates, emissions control modifications, potential updates to suspension components or braking systems (e.g., introduction of front disc brake on some later models). The core design and engine remained largely consistent, highlighting its enduring appeal and robust engineering.

Manufacturing Location:

Japan (primary)

Longevity:

The TW200 has enjoyed a remarkably long production run, testament to its practical design and loyal following.

🏆 Awards & Recognition

Recognition Type:

Cult Following and Longevity.

Award Details:

While not receiving formal industry awards in the traditional sense, the TW200 is highly regarded by its owners for its unique capabilities, reliability, and ease of maintenance, leading to a dedicated user base and a reputation as an iconic 'go-anywhere' machine.