Target Audience:
Yamaha TW200 owners for DIY maintenance, repairs, and enthusiasts seeking in-depth knowledge
Vehicle Segment:
Lightweight dual-sport, trail riding, all-terrain exploration
Niche Appeal:
Renowned for its exceptionally wide rear tire, offering unique traction and stability in soft terrain (sand, mud).
Manual Strength:
Factory accuracy and detail, essential for correct repair and maintenance procedures.
Value Proposition:
Empowers owners to perform their own maintenance, saving costs and gaining deep understanding of their motorcycle.
Engine:
Complete overhaul, troubleshooting, tuning, lubrication, cooling, fuel system, ignition system, exhaust system
Transmission:
Clutch operation, gearbox inspection, gear shifting mechanisms, lubrication, troubleshooting
Chassis And Frame:
Frame inspection, swingarm, steering head bearings, component mounting
Suspension:
Front fork service (seals, oil, damping), rear shock absorber inspection and replacement, linkage system
Brakes:
Front and rear brake system maintenance, caliper service, brake fluid replacement, bleeding procedures, disc and pad inspection
Electrical System:
Wiring diagrams, battery maintenance, charging system (stator, regulator/rectifier), ignition system components (CDI, coil, spark plug), lighting, horn, starter motor
Fuel System:
Carburetor disassembly, cleaning, adjustment, fuel tank, fuel petcock, fuel lines
Cooling System:
Air cooling system analysis, fin cleaning, heat dissipation considerations
Wheels And Tires:
Wheel bearing inspection and replacement, spoke tensioning, tire pressure recommendations, tire removal and installation
Bodywork And Fittings:
Fender removal and installation, seat, handlebars, control levers, footpegs, mounting hardware
Routine Maintenance:
Oil changes, filter replacement, chain adjustment, spark plug replacement, air filter cleaning/replacement, brake fluid checks, tire pressure checks
Troubleshooting:
Diagnostic charts, symptom-based issue resolution for engine, electrical, and mechanical problems
Engine Repair:
Top-end rebuild (cylinder, piston, rings), valve clearance adjustment, camshaft removal/installation, complete engine disassembly and reassembly
Carburetor Service:
Disassembly, cleaning, jet replacement, float adjustment, idle speed settings
Electrical Diagnostics:
Using multimeters, testing components, diagnosing charging system issues, ignition timing checks
Suspension Overhaul:
Front fork seal replacement, fork oil viscosity and level specifications, rear shock absorber servicing
Brake System Maintenance:
Pad replacement, caliper piston service, brake line flushing, master cylinder service
Wheel And Tire Service:
Tire mounting and balancing, spoke replacement and truing
Depth Level:
Comprehensive (from basic checks to full engine and electrical system rebuilds)
Visual Aids:
Hundreds of detailed photos and exploded diagrams
Instruction Style:
Step-by-step instructions for all procedures
Engine Type:
Four-stroke, SOHC, Air-cooled
Bore X Stroke:
67.0 mm x 55.7 mm
Horsepower Estimated:
Approx. 16-17 HP @ 7,500 RPM (for 1987-1990 models)
Torque Estimated:
Approx. 11.5 lb-ft @ 5,500 RPM (for 1987-1990 models)
Carburetor:
Mikuni VM26 (single, constant velocity)
Fuel Tank Capacity:
Approx. 1.6 US gallons (6.0 L)
Ignition System:
CDI (Capacitor Discharge Ignition)
Spark Plug Type:
NGK CR7E (or equivalent)
Oil Type:
Yamalube 4 (or API SE, SF, SG, SH, SJ, SL, SM or SG/CD, SH/CD, SJ/CD, SK/CD, SL/CD, SM/CD SAE 20W-40)
Oil Capacity With Filter Change:
Approx. 1.50 L (1.59 US qt)
Oil Filter Part Number:
Yamaha 5H0-13440-00-00 (or equivalent aftermarket)
Transmission Type:
Constant Mesh, 5-speed
Clutch Type:
Wet, multiple disc
Gear Ratios Primary:
3.042 (73/24)
Gear Ratios 1St:
2.833 (34/12)
Gear Ratios 2Nd:
1.778 (32/18)
Gear Ratios 3Rd:
1.333 (28/21)
Gear Ratios 4Th:
1.111 (25/23)
Gear Ratios 5Th:
0.917 (22/24)
Transmission Oil Type:
Yamalube 4 (or SAE 10W-40 API SE, SF, SG, SH, SJ, SK, SL, SM or SG/CD, SH/CD, SJ/CD, SK/CD, SL/CD, SM/CD)
Transmission Oil Capacity:
Approx. 0.65 L (0.69 US qt)
Engine Oil Change:
Every 2,000 km (1,200 miles) or 6 months
Air Filter Cleaning:
Every 1,000 km (600 miles) or 3 months; Replace annually
Spark Plug Inspection:
Every 4,000 km (2,400 miles) or 12 months
Valve Clearance Check:
Every 8,000 km (4,800 miles) or 12 months
Chain Lubrication And Adjustment:
Every 500 km (300 miles) or 1 month
Brake Fluid Replacement:
Every 2 years (regardless of mileage)
Engine Oil Viscosity:
SAE 20W-40
Transmission Oil Viscosity:
SAE 10W-40
Brake Fluid Type:
DOT 3 or DOT 4 (glycol-based)
Fork Oil Type:
Yamaha Fork Oil 10W (or equivalent)
Fork Oil Level:
Check manual for precise measurement, typically around 100-120 mm from the top of the inner tube with spring removed and fully compressed.
Carburetor Gumming:
Can occur if left to sit with fuel; requires regular cleaning and fuel stabilizer for long-term storage.
Rear Suspension Preload:
Stock rear suspension can be soft under heavy loads; manual covers adjustment.
Valve Adjustment Frequency:
While interval is 8000km, some owners find it beneficial to check slightly sooner, especially if performance changes are noted.
Chain Wear:
Due to the wide tire, there can be increased drag on the chain; regular lubrication and adjustment are critical for longevity.
