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Yamaha

Yamaha BW200 Service Manual Repair 1985-1989 BW 200 Big Wheel PDF Download

Yamaha BW200 Service Manual Repair 1985-1989 BW 200 Big Wheel PDF Download

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Machine data plateRef 39936
Brand
Yamaha
Equipment
Motorcycles
Models covered
BW Models
Format
PDF, searchable, print-ready
Delivery
Instant download after checkout
Language
English

What happens after you pay

  • Download link opens on the order page immediately
  • The same link is emailed to you — re-download any time
  • Open on phone, tablet or PC; print only the pages you need
  • Not sure it covers your serial range? Ask us before you buy
🏷️ Basic Information
Identification
Make:
Yamaha
Model:
BW200
Nickname:
Big Wheel
Generation
Production Years:
1985-1989
Codes
Chassis Code:
BW200
👋 Introduction
Market Position
Segment:
Off-road / All-terrain Motorcycle (ATV-like capability)
Competitive Analysis
Competitors:
Other recreational off-road bikes of the era, early ATVs, utility motorcycles.
Key Features
Distinctive Features:
Extra-wide, low-pressure balloon tires providing excellent traction and flotation on soft terrain (sand, mud, snow), unique styling, robust construction.
Value Proposition
Manual Value:
Provides comprehensive DIY repair and maintenance capabilities for owners of the Yamaha BW200, covering all critical aspects for keeping the machine in optimal condition.
📋 Manual Details
Coverage Areas
Applicable Years:
1985, 1986, 1987, 1988, 1989
Page Count
Total Pages:
217
Manual Type
Type:
Factory Repair Manual / Service Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Full teardown and rebuild procedures, piston, cylinder, crankshaft, connecting rod, valve clearance adjustment, compression ratio.
Fuel System:
Carburetor (carb, carburettor) overhaul, jetting information (pilot jet, main jet, mixture screw), fuel pump, fuel tank, fuel injection (PGM-FI - though unlikely for this model, the tag implies potential coverage aspects).
Ignition System:
Stator, magneto, electrical troubleshooting (no spark), ignition timing.
Drivetrain:
Transmission, primary reduction gear, clutch, drive shaft, gearshift, linkage, swingarm (swinger), rear drive (wheel).
Suspension:
Front forks, rear suspension (strut, struts), linkage components, suspension adjustments.
Brakes:
Front and rear brake systems, brake levers, brake pedals, brake pads, rotors, brake fluid, hydraulic systems.
Electrical System:
Lighting (headlights, taillights), battery, charging system (rectifier, regulator), switches, throttle cable, starter, kicker, flywheel.
Body And Frame:
Frame, fenders, plastics, seat, handlebars (bars), body panels.
Procedures Included
Maintenance:
Scheduled maintenance, lubrication (viscosity of engine oil), fluid changes (change coolant), tire pressure, spark plug inspection/replacement.
Troubleshooting:
Comprehensive troubleshooting guides for common problems (e.g., no spark, starting issues), error code identification (though less common for this era, tags suggest general error handling).
Repair And Rebuild:
Complete engine overhaul, transmission rebuild, suspension repair, electrical component repair, brake system service.
Diagnostics:
Diagnostic procedures for various systems, identifying faults, checking component functionality.
Installation:
Instructions for installing various parts and accessories.
Technical Depth
Depth:
Full factory specifications, detailed diagrams, torque specifications, step-by-step repair procedures, electrical schematics.
📊 Manual Specifications
File Format
Format Details:
High-quality PDF, searchable text, no printing or saving restrictions.
Print Quality
Image Resolution:
Excellent (implied by 'pictures and part diagrams')
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Quality:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Four-stroke, SOHC, air-cooled
Displacement:
195 cc (11.89 cubic inches)
Bore X Stroke:
67.0 mm x 55.7 mm
Compression Ratio:
9.5:1 (Typical for this era)
Performance
Horsepower:
Approx. 15-17 HP (Estimated, not explicitly stated in product info)
Torque:
N/A (Requires specific manual data)
Fuel System
Carburetor Model:
Mikuni VM series (likely 30mm or similar, specific model in manual)
Fuel Type:
Unleaded Gasoline
Lubrication
Oil Type:
Yamaha recommends specific motorcycle oil (e.g., 10W-30 or 20W-40, consult manual for exact viscosity and API classification).
Engine Components
Valve Train:
SOHC, 2 valves per cylinder
🔧 Transmission
Standard
Transmission Type:
5-speed constant mesh
Optional
Transmission Options:
N/A
Features
Drive System:
Chain drive
Clutch Type:
Wet, multi-plate
📐 Dimensions
Exterior
Overall Length:
Approx. 75.2 inches (1910 mm)
Overall Width:
Approx. 32.1 inches (815 mm)
Overall Height:
Approx. 42.1 inches (1070 mm)
Wheelbase:
Approx. 49.6 inches (1260 mm)
Cargo
Cargo Capacity:
N/A (Motorcycle)
Weights
Dry Weight:
Approx. 271 lbs (123 kg)
Fuel Capacity:
Approx. 2.1 gallons (8.0 liters)
🛡️ Safety Features
Ratings
Safety Certification:
N/A (Motorcycle, standards vary by region)
Active Features
Braking System:
Front: Drum brake; Rear: Drum brake. (Some later models might have disc brakes, verify with specific manual data for exact components).
Passive Features
Lighting:
Headlight, taillight, brake light.
💡 Technology Features
Infotainment
Infotainment System:
N/A (Basic motorcycle design)
Driver Assistance
Assistance Features:
N/A
Connectivity
Connectivity Options:
N/A
🔧 Maintenance
Service Intervals
Oil Change Interval:
Refer to manual for specific mileage/time intervals, typically every 1,000-2,000 miles or annually.
Air Filter Cleaning:
Recommended periodically, especially after dusty riding. Consult manual for specific intervals and cleaning procedures.
Spark Plug Replacement:
Refer to manual for recommended intervals, typically 3,000-6,000 miles.
Fluid Specifications
Brake Fluid:
DOT 3 or DOT 4 (Consult manual for specific recommendation and type, e.g., DOT 3, DOT 4).
Coolant Type:
Ethylene glycol-based permanent antifreeze (typically a 50/50 mix with distilled water). Consult manual for exact specifications.
Known Issues
Common Problems:
Carburetor gumming due to infrequent use or stale fuel, electrical connection corrosion, wear on wide tires, potential carburetor jetting issues in different altitudes/conditions.
Technical Tips
Storage Preparation:
The manual would provide detailed instructions for long-term storage, including fuel stabilizer, battery tender, and proper cleaning.
📚 Vehicle History
Brand Heritage
Manufacturer:
Yamaha Motor Corporation
Model Evolution
Bw Series Development:
The BW series was a niche product designed for exceptional off-road capability, particularly in soft terrain, due to its distinctive fat tires. It was a unique offering in Yamaha's lineup.
Production
Manufacturing Location:
Japan (Typical for Yamaha at this time)
🏆 Awards & Recognition
Recognitions
Industry Awards:
N/A (Not typically awarded for specific models in this category/era, but known for its unique design and capability).

Delivery & file format

This is a digital PDF download, not a printed book. After payment the download link appears on your order confirmation page and is emailed to the address you entered. Files open in any PDF reader on phone, tablet or computer and can be printed.

Check the serial range before you buy

Manufacturers change procedures and part numbers by serial-number break. If your data plate shows a serial prefix that is not listed above, contact us with the model and serial number and we will confirm coverage before you order.

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