Yamaha TW200 TRAILWAY Workshop Repair Manual All 1987-2009 ModelS COVERED

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🏷️ Basic Information Identification Make: Yamaha Model: TW200 TRAILWAY Model Nickname: Trailway Codes Vin Prefix Chassis Code: JY4 Engine Code General: 4CS 👋 Introduction Market Position Segment: Dual-sport, Enduro, Light...

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类型: Motorcycle

斯库: 271112

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

产品多属性

Description

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

TW200 TRAILWAY

Model Nickname:

Trailway

Codes

Vin Prefix Chassis Code:

Engine Code General:

👋 Introduction

Market Position

Segment:

Dual-sport, Enduro, Light Trail Motorcycle

Target User:

Enthusiasts, DIY mechanics, professional technicians working on Yamaha TW200 models.

Competitive Analysis

Comparison Points:

Covers a wide range of model years, offering a cost-effective alternative to OEM manuals for older models.

Key Features

Download Benefit:

Instant access to critical repair and maintenance information for timely servicing.

Information Type:

Technical service manual, providing in-depth procedures.

📋 Manual Details

Coverage Areas

Model Years Covered:

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

Page Count

Estimated Page Count:

Manual Type

Type:

Workshop Service Repair Manual

Language

Language:

English

Format

Format:

Digital Download (PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, disassembly, inspection, overhaul, top end, bottom end, piston, rings, cylinder, crankshaft, camshaft, valve train.

Fuel System:

Carburetor tuning and overhaul, fuel tank, fuel lines, fuel pump (if applicable).

Ignition System:

CDI unit, ignition coil, spark plug, timing.

Electrical System:

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

Transmission Drivetrain:

Gearbox inspection, repair, clutch operation and service, final drive (chain, sprockets).

Suspension:

Front forks (oil change, seal replacement, spring inspection), rear shock absorber, linkage inspection.

Brakes:

Front and rear brake systems (drum or disc depending on model year variant), brake fluid, caliper/master cylinder service, brake pad/shoe replacement.

Frame Bodywork:

Frame inspection, subframe, body panels, fenders, seat, handlebars, controls.

Wheels Tires:

Wheel bearing inspection and replacement, spoke tensioning, tire mounting and balancing.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, chain lubrication and adjustment, air filter cleaning/replacement, spark plug checks, valve clearance adjustments.

Troubleshooting:

Diagnostic charts, common problem identification and solutions for starting issues, engine performance, electrical faults.

Repair Overhaul:

Step-by-step instructions for complete engine rebuilds, gearbox overhauls, suspension rebuilds, brake caliper servicing.

Component Replacement:

Detailed guides for replacing parts such as pistons, valves, clutch plates, bearings, seals, cables, and bulbs.

Technical Depth

Depth Level:

Comprehensive (from basic maintenance to complete engine and chassis rebuilds)

Diagnostic Capabilities:

Includes torque specifications, clearance measurements, electrical resistance values, and diagnostic flowcharts.

📊 Manual Specifications

File Format

Format:

Print Quality

Quality:

High-resolution, printable pages with clear diagrams and text.

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Four-stroke, SOHC, air-cooled

Displacement:

196 cc (12.0 cu in)

Bore X Stroke:

67.0 mm x 55.7 mm (2.64 in x 2.19 in)

Compression Ratio:

9.5:1 (Typical, may vary slightly by year)

Performance

Horsepower:

Approx. 16-18 HP (at crankshaft, depending on year and tuning)

Torque:

Approx. 11-13 lb-ft (at crankshaft, depending on year and tuning)

Fuel System

Carburetor Type:

Mikuni VM26 (typically)

Fuel Tank Capacity:

Approx. 1.6 gallons (6.1 L)

🔧 Transmission

Standard

Type:

5-speed constant mesh

Clutch Type:

Wet, multi-plate

Drive Type:

Chain Drive

Features

Gear Ratios:

Specific ratios detailed within the manual.

Clutch Adjustment:

Cable free play adjustment procedures included.

📐 Dimensions

Exterior

Overall Length:

Approx. 81.1 in (2060 mm)

Overall Width:

Approx. 32.1 in (815 mm)

Overall Height:

Approx. 42.1 in (1070 mm)

Wheelbase:

Approx. 52.0 in (1320 mm)

Weights

Dry Weight:

Approx. 258 lbs (117 kg)

Curb Weight:

Approx. 275 lbs (125 kg)

Cargo

Rear Rack Capacity:

N/A (but often equipped with aftermarket racks)

🛡️ Safety Features

Ratings

Crash Test Ratings:

N/A (motorcycle safety ratings are not standardized like automobiles)

Active Features

Braking System:

Front: Disc (later models) or Drum; Rear: Drum.

Lighting:

Halogen headlight, taillight, turn signals.

Passive Features

Tire Design:

Wide profile tires for increased stability and off-road traction.

💡 Technology Features

Infotainment

Display Features:

N/A (Basic analog instrumentation: speedometer, odometer, indicator lights).

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 2,000 km (1,200 miles) or 6 months, whichever comes first.

Oil Filter Replacement:

Every 2 oil changes, or as per manual recommendation.

Air Filter Cleaning:

Every 1,000 km (600 miles).

Spark Plug Inspection:

Every 2,000 km (1,200 miles).

Valve Clearance Check:

Every 4,000 km (2,500 miles).

Chain Lubrication Adjustment:

Every 500 km (300 miles) or after riding in wet conditions.

Fluid Specifications

Engine Oil Type:

SAE 10W-40 API SE or SG classification (specific grades may vary, consult manual for precise recommendation)

Engine Oil Capacity:

Approx. 1.6 L (1.7 US qt) for oil change with filter.

Brake Fluid Type:

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

Fork Oil Type:

SAE 10W fork oil (specific volume per leg detailed in manual)

Known Issues

Carburetor Cleaning:

Occasional cleaning of the Mikuni carb may be required due to fuel deposits, especially with infrequent use.

Rear Shock Wear:

The original rear shock absorber may show signs of wear (leaking, loss of damping) after extensive use, requiring replacement or rebuilding.

Countershaft Seal Leaks:

Potential for minor oil leaks from the countershaft seal.

📚 Vehicle History

Brand Heritage

Manufacturer:

Yamaha Motor Corporation, known for innovation and performance in powersports.

Model Evolution

Introduction Year:

Design Philosophy:

Designed as a versatile trail-riding motorcycle with unique wide tires for enhanced off-road capability and stability.

Key Changes 1987-2009:

Updates primarily in braking systems (introduction of front disc brake on some models), minor aesthetic changes, and potential internal engine refinements.

Production

Production Period:

1987 - Present (with significant coverage up to 2009 by this manual)

Manufacturing Location:

Japan (primary)

🏆 Awards & Recognition

Recognitions

Industry Acclaim:

While not typically awarded industry 'awards' in the traditional sense, the TW200 is recognized for its reliability, versatility, and unique niche appeal among dual-sport riders.

Ratings

Consumer Satisfaction:

Consistently receives positive user reviews for its durability and go-anywhere capability.

Certifications

Emission Standards:

Meets relevant emission standards for its production years, with detailed information on specific tuning for compliance found in the manual.