This Official 2001-up Yamaha TW200 Trailway Factory Service Manual provides repair, maintenance and service information for 2001-up Yamaha TW200 Trailway motorcycles. Most of the information is useful for the 1987-2000 models as well.
Clymer repair manuals provides step-by-step procedures based upon the complete disassembly of the motorcycle. This hands-on experience combined with extensive research results in a manual that is both user-friendly and detailed. Contains hundreds of original photos, exploded views, drawings, specifications and charts to illustrate each job. Also features shortcut repairs and high-performance modifications.
Whether you're interested in routine maintenance tasks, troubleshooting, or more extensive repairs, the in-depth coverage provides indispensable information about your KLR650.
Here is the O-Ring that fits in the carburetor manifold. This is the manifold that holds the carb up to the cylinder head. The O-Ring mounts between this manifold and the cylinder head. When this O-Ring fails it allows air into your cylinder and makes your Air Fuel ratio too lean which causes the engine to run too hot.
Repair leaking carburetor or worn out float needle assembly.
The Phillips screws in Japanese motorcycles are not really Phillips screws. They are actually Japanese Industrial Standard (JIS) screws that are very easy to strip with Phillips head drivers.
Rebuild your crusty carburetor with parts from the same manufacturer the OEM companies use. Included in the kit are all necessary gaskets, O-rings, float valve and jets you need to rebuild your carburetor to like new condition.
Twin Air Filter's patented design, high quality materials and superior construction deliver unbeatable performance and protection - and make Twin Air Filters the hands-down choice of more World and National Champions than all other filters combined.
The air filter is your engine's only protection against the elements, and your stock filter isn't up to the task. Replace it with a Twin Air-the #1 filter system proven on motocross tracks around the world.
Twin Air's fused layers of open-pore foam and fine inner foam trap even the smallest particles-without restricting airflow.
FunnelWeb ProLine Filter Highlights:
Like all FunnelWeb filters, the ProLine Filter features profile cut, single layer, single density foam that doubles the external surface area of the filter without increasing the original filter size. The ProLine Filter traps dirt, dust, sand and mud over a larger area on its outer surface, ensuring optimal air flow is maintained for maximized engine performance and reliability.
The single layer, single density polyurethane foam has the added advantage of being easy to clean and the ability to maintain its original shape after numerous washes. Overall, compared with conventional foam filters, FunnelWeb offers more protection from dirt ingestion, has longer service intervals and maintains high airflow rates when dirty.
This filter replaces the stock air filter, fitting inside the air box.
Thick, flat foam, greaseless sealing ring ensures maximum contact with your airbox while acting as a breathable gasket for increased air passage
Features:
The EJK evolved out of the need to address the ever-increasing complexity of factory fuel injection. For the newcomer to the market or professionals wanting an easier method for tuning fuel injection, the EJK is a customizable solution for the rider that wants to take control of their tuning needs.
This unit is a piggy-back EFI controller because it does not replace the stock ECU, but rather monitors the signals to the injectors and makes fuel adjustments based on the mode settings. The GEN 3 has a push button interface allowing access up to 6 different modes to allow for quick fine tuning by the end user without needing a computer.
Key Features:
Acerbis 3.9 gal tank adds function and great looks to your DRZ. This high capacity fuel tank incorporates modern lines and high quality construction that can't be beat. Includes gas cap, petcock and all mounting hardware.
Get better range from your XR650L by adding a Clarke 4.7 gallon fuel tank. Cannot use stock shrouds.
Available in Natural, White, Black, and Red. Natural color is recommended if you wish to easily see the fuel level in the tank. Includes cap, uses stock petcock.
If you need a replacement cap for your Acerbis tank, why not go bling? These caps have a carbon fiber pattern molded into them that is extremely realistic. Looks like the real thing. Topping off the cap is a CNC Machined metal vent cap. This eliminates the need for a lengthy vent tube that gets in the way. The vent cap allows air to vent into the tank but does not allow fuel to splash out during normal use or during a tip over.
These caps fit Acerbis tanks only.
This rear master cylinder guard is fabricated from 2mm thick 5052 marine grade alloy, CNC machined from one piece for maximum strength and polished for great looks. Made to cover and protect the master cylinder from all kinds of situations, it is supplied with all necessary hardware.
Protect your brake rotor and fork lowers from mud and debris. Choose between black or white.
Construction of these handguards feature heavy duty aluminum guards with colored plastic deflector shields. They offer great protection from those trees that jump out at you on the trail and the cold wind and rain you encounter on the street. They feature a deep bend on the outer bar end for maximum freedom of hand placement and high quality bar mounts on the inside.
Select your desired color.
Must add the corresponding size mounts to fit your handlebar.
For DR650 or other models with long levers add the optional universal fit Spacer Kit so you don't have to cut the balls off the end of your levers when installing these handguards. (May require additional adjustment or modification on some models.)
Please Note: These handguards do not fit the Yamaha T7
Always carry a spare master link when out on the trail.
Master links are not interchangeable. Be sure to check the manufacturer and series on your chain.
These do not fit the TW200 or XT250. Only for 520 or 525 chains, Please verify chain size.
Quality steel front sprockets. Choose 13T through 15T. The stock size for the XRL is 15T. Go down in tooth count for faster acceleration.
These quality JT sprockets are made from the finest 545C high carbon steel and are then heat treated and hand finished to meet or exceed OEM standards. Outlasts many mild steel or surface hardened sprockets as much as two and three times over.
This kit will replace your stock sprocket bolts and nuts with new hardware.
Factory Honda replacements in a convenient kit.
JT steel rear sprockets are manufactured using only the finest grade of C49 high carbon steel.
Two styles of rear sprocket were used on the DR350. The 90-95 'S' and 'SE' (street legal) models have a cush drive hub. The 96-99 'S' and 'SE' as well as all of the 'dirt only' models have a non-cush rear hub. Select your sprocket accordingly. If you are not sure, look at your bike. If the sprocket is bolted directly to the wheel hub you have a non-cush model. If your sprocket is bolted to a separate sprocket carrier you have a cush drive model.
High quality steel rear sprockets from 39 to 53 teeth.
Sprocket color may differ depending on size.
Genuine Kawasaki replacement chain guide. This guide mounts to the lower swing arm.
Complete chain and sprocket replacement packages.
Seat Concepts seats are constructed using a foam material that is a much higher quality than OEM seat foam. Their proprietary formula provides a plusher ride, while still offering the necessary amount of support. Their unique comfort shape maintains a similar contour to stock at the front of the seat so the rider’s legs are not spread farther apart, but tapers out towards the mid-point to distribute rider weight over a greater area.
Complete seats are built by Seat Concepts on a new seat pan and come ready to be installed on your bike.
| Width: | 10" (254mm) |
| Height: | Same as OEM |
The Go Cruise cruise control mounts over the throttle grip and rests on the brake lever to hold your throttle open, allowing you to stretch and rest your hand on long rides. Installs and removes in seconds with no tools. You can roll off the throttle manually to disengage the Go Cruise.
Protect your thumbs from blisters caused by riding on the inside of your grips.
Sold in Pairs.
Designed to enhance the appearance of your TW200, yet provide greater riding distance per tankful. This larger fuel tank has double the capacity of the stock tank at 3.6 Gallons, yet very slim and sleek. This tank has a custom design that will allow the use of OEM & Maier side covers. These tanks are made with POLYETHYLENE CROSSLINK for extra strength and durability.
Comes with New Screw Cap.
Requires OEM/Stock petcock and oval rubber grommets for install.
If you do not have the grommets or if your O.E. grommets are in poor condition you can add these to your tank order.
An upright Dakar Rally inspired shield designed to protect the rider without interfering with off-road riding. For on-road riding the Rally shield protects the rider’s core from fatiguing air blasts while keeping the head in clean air. Duck behind it in the cold or the rain to keep from experiencing the brunt of the elements. During off-road riding the Rally windshield protects the rider from any amount of mud, dust, roots, rocks, or branches without becoming invasive. Whether standing on the pegs or ducking behind it, you will be impressed at the protection it offers.
The Rally shield for the TW200 is 13 inches tall, 12.5 inches wide at the bottom, 9 inches wide at the top, and made from military grade 1/8 inch cast acrylic in either clear or tint.
Outer Clutch Cover O-Ring, Inner Clutch Cover Gasket, Stator Cover Gasket.
Sold individually, not as a kit
Providing unbeatable performance and exceptional value, Hiflofiltro is the best-selling brand of aftermarket filters for motorcycles, scooters, and ATVs worldwide. The filters are also supplied to original equipment manufacturers as well as private label brands.
Grab our 5-pack and save both time and money!
Choose standard bore top end, big bore top end or a complete gasket set for the standard bore motor. These are high-quality gasket sets from Athena.
GoldPlug is the gold standard in engine protection.
Stainless steel drain plug with an extremely strong magnet that picks up metal flakes in your oil.
10MM Thread
The PSR Oil Filler Caps are CNC machined from high quality aluminum and come with an E-clip that is already safety wired to a mounting tab. The wire is covered with silicone tubing that will not melt or discolor. Available in silver, black and gun metal.
The idler gear is one of the few plastic components in the DR650 that can significantly impact engine performance if it fails or breaks.
This gear is crucial for driving the oil pump, which ensures proper oil circulation throughout the engine. In the absence of this component, complete engine failure may occur. While the idler gear is not frequently cited as a common failure point in the DR650 engine, failures have been reported, typically manifesting as either a fractured gear or stripped teeth.
During inspection, it is essential to check for any cracks, chipped areas, or missing teeth on the idler gear. Replacing the gear is a straightforward procedure, and it is advisable to do so while the clutch side case cover is already removed for other maintenance tasks, such as NSU screw replacements or clutch hub bushing replacements.
This component is a Genuine Suzuki part.
New starters that are manufactured to meet or exceed OEM specifications. Pull out your old starter, put in this new one and go riding. These units are built to provide a longer life than the OEM unit with these features:
This is a genuine Suzuki part. We recommend installing a countershaft seal retainer to prevent the countershaft seal from popping out while riding.
This high output stator will allow you to run brighter lights, heated gear, heated grips, etc. From ElectroSport
CNC machined from 6061 Aluminum by the crew at Warp 9. This upper triple clamp will help to get the bars out of your lap on the XR650L. It allows for six different bar positions (three mount positions and reversible offset mounts). Uses the stock key switch and works with the handlebar lock. Speedometer and indicators all use mounting positions as well.
This clamp comes with 1-1/8" handlebar mounts.
Original Kawasaki factory replacement levers for your KLX230.
Order up your new levers here! If you keep breaking levers, you might want to think about a set of hand guards to protect them in case of a fall.
OE style clutch lever.
Replace your Bent or Broken Levers.
TW200 fitment 1987-2000 year models with Drum Front Brake or 2001-2014 year models with Disc Front Brake.
Stamped from heavy gauge stainless steel, Giant Loop® Mounts bolt onto virtually any motorcycle, snowmobile, snow bike, ATV, UTV, SxS, 4×4—and even boats. These mounts help keep straps away from hot exhaust while shortening strap lengths for maximum stability and helps make installation of Giant Loop Saddlebags, Panniers, Dry Bags, and Tank Bags even easier.
Sold as a set of two (2).
Not only are Pro Moto Billet Cargo Racks brutishly strong and functional, but they look great too. Each cargo rack is methodically engineered, then CNC machined on-site from a 1/2 inch thick plate of USA made 6061 aluminum by master machinists.
The cargo racks are then hard clear anodized for durability. PMB uses only stainless steel fasteners for worry-free years of riding. Excellent instructions and all necessary hardware is included. 10.5"Wx11.5"L
Need to mount your turn signals to your new Pro Moto Billet Rack? Just add a set of CNC machined aluminum Turn Signal Brackets.
These Sequential Turn Signals are available in a 2 pack or 4 pack short stem with 7 LEDs.
Matte Black, plastic body with smoke lens and 8mm mount bolt.
Specifications
These turn signal relocation brackets from ProMoto Billet provide an easy way to move the stock turn signal lights, useful if you find them getting in the way of your luggage configuration.
These brackets may utilize an existing hole in some of the rack side brackets, though many applications will require drilling or fabricating in order to mount properly.
Inexpensive way of getting the factory look. Adds 1/2" of width to any standard foot peg. These will give you a much more stable platform when standing on the pegs.
Sold in pairs.
Fastway offers a large ADV peg that is 4.75" long and 2.25" wide. With these pegs you can adjust the camber with their patented FKMS Kamber bolt. ´Tilt´ your pegs to increase comfort, or to give better squeeze on your bike. These pegs come with two sets of F3 cleats (one standard, one long). You can order serrated or spiked cleats separately.
These Adventure pegs are offered in several colors, but some colors may require extra time, call for availability.
Pivot Pegz have set a new standard in footpeg performance and quality, and now they are even better. The new Mark 4 Pivot Pegz are wider & stronger. They have a unique multi-directional grip pattern and a wide, open design to reduce mud packing. The Mark 4 also incorporates new heavy duty, long life springs and they come with a lifetime warranty.
Pivot Pegz aim to build the best footpegs in the world and they really do perform as good as they look. Here's a bonus for those riders with size 13 boots - the pivoting action of these pegs makes it easier to get your toe under the shift lever.
See below for extenders for these pegs to make them true ADV pegs!
This is the ultimate adventure bike platform, it measures 2.25" wide, 4.75" long.
Patented adjustable collars make it easy to run them in the 'standard' or 'low boy' positions on most bikes.
Gain more room for bulky boots, or for longer legs. Fastway Adventure pegs come with two sets of F3 cleats, one standard, one long. Kamber bolts lets you adjust the 'tilt' of your pegs to increase comfort, or to give better squeeze on your bike.
Finally, the ultimate Adventure peg, from the folks at Fastway - Pro Moto Billet. This peg is big enough to stand on all day with no fatigue, it measures 2.25" front to back and is 4.75" wide.
In addition to the big size, you can also adjust the camber with their patented FKMS Kamber bolt. ´Tilt´ your pegs to increase comfort, or to give better squeeze on your bike. You can further customize them with 3 styles of patented adjustable threaded cleats. Take your traction from comfortable to gnarly. Fastway Adventure pegs come with two sets of F3 cleats, one standard, one long. You can also order serrated (F5 - bottom left image) or spiked (F6 - bottom right image) cleats separately.
These Adventure pegs are offered in several colors, but some colors may require extra time, call for availability.
The ultimate Adventure peg, from the folks at Fastway - Pro Moto Billet. This peg is big enough to stand on all day with no fatigue, it measures 2.25" front to back and is 4.75" wide.
In addition to the big size, you can also adjust the camber with their patented FKMS Kamber bolt. ´Tilt´ your pegs to increase comfort, or to give better squeeze on your bike. You can further customize them with 3 styles of patented adjustable threaded cleats. Take your traction from comfortable to gnarly. Fastway Adventure pegs come with two sets of F3 cleats, one standard, one long.
These Adventure pegs are offered in several colors, but some colors may require extra time, call for availability.
Mounting these pegs to your KLR takes just a bit of work.
Please see link to the instructions below. These apply to the ADV and Evolution AIR Peg as well as the Evolution II pegs referred to in the instructions.
Greatly eases basic chain maintenance, tire changes, parking, cleaning, etc. All necessary hardware is included. Installs using basic hand tools. Tough black powder coated finish.
For riders who wish to run the centerstand and the lowered footpegs we recommend installing a Warp 9 brake pedal. The Warp 9 pedal is arched to give the necessary clearance under the pedal.
Tapered roller bearings provide decreased maintenance, less wear, smoother operation and longer life.
This set of high quality replacement steering stem bearings includes:
Made with heat-treated carbon steel for longer wear life and reduced galling.
This will give you a complete SET (Front and Rear) of brake pads.
Includes front and rear brake pads.
Includes front and rear brake pads.
Sport Carbon pads:
Sintered Pads:
Race Sintered:
Includes front and rear brake pads
Includes front and rear brake pads
Kit includes front and rear brake pads.
Includes front and rear pads
Includes pads for both front and rear.
Small Wheel models have a 17" Front Wheel and 14" Rear Wheel.
Premium quality EBC Rear brake shoes.
Auxiliary fuel tanks mount to handlebars, forks, or rear racks.
Quality replacement rear fender from Maier.
The GP-1 Dual Sport Tire from IRC is designed to provide the best possible handling and control for both on and off the pavement. Special knobs penetrate loose surfaces for excellent traction, braking and cornering off the road yet won't wear off as fast as a full knobby when used on the street. Features include:
Available for Front 3.00x21 only
Heidenau tires are made in Germany and they are high quality motorcycle tires for street, off road and adventure riding.
Durability, It’s about the Rubber
Heidenau’s compound uses a high natural rubber content, and there’s a lot on there. This naturally resilient compound, combined with sturdy Belted construction, makes for one of the most trusted, longest lasting tires available to long distance travelers.
K60 Tread design:
The K60’s interrupted block chevron pattern makes for a respectable off road tire that’s smooth on the street.
A kit consisting of 15 (9 front - 6 rear) KLR650 rotor bolts, enough to do the front and rear.
Class 10.9 steel rotor bolts provide excellent sheer strength and include medium-strength threadlock patches to securely fasten your rotor
Use this installation tool from Cogent to be sure that your Cogent Drop-in Dynamic Cartridges are installed correctly. A strong magnet in the end holds the cartridge firmly while you lower it into your fork leg. Then slide the spring over the tool until it holds the DDC down, then gently remove the tool. That simple. Never again question if it is properly seated on the damper rod.
Works equally well for removal when you need to change your fork oil. Also works great with Race Tech Emulators.
Having the proper fork oil level is imperative to the handling of your bike. Setting the correct fork oil level is a snap with this fully adjustable gauge. The adjustable aluminum level plate can be set from 0 to 295mm. The oil reservoir has single milliliter markings up to 60ml.
Being able to accurately tune your forks by adjusting the oil level can make them better resist brake dive or bottoming. Oil level should be thought of as a fine tuning method to make your choice of spring rate work perfectly for your bike.
Disclaimer: Lowering the front and/or rear of your motorcycle will change the geometry and may affect the handling, use caution after making changes/adjustments.
Lowers the rear suspension 1.5 inches. Precision machined from billet aluminum and gold anodized.
Set your bike apart with a custom exhaust look. Withstands direct heat up to 2000°F.
This universal heat shield provides a great look at a great price.
Low friction 'triple lip' seal design. Oil seals last 3-4 times longer that OEM seals. Kit includes fork seals and dust wipers.
CNC machined from 6061 Aluminum by the crew at Warp 9. This upper triple clamp will help to get the bars out of your lap on the XR650L. It allows for six different bar positions (three mount positions and reversible offset mounts). Uses the stock key switch and works with the handlebar lock. Speedometer and indicators all use stock mounting positions as well.
This clamp comes with 1-1/8" bar mounts that work perfectly with the tapered handlebars included. Then there is a new set of ProGrip 714 Rally Grips.
Don't get burned! Giant Loop's ingeniously simple and effective exhaust shield protects bags and bodywork from heat damage. The Hot Springs Heat Shield helps avoid the meltdown, preventing bags and side panels from touching your bike's exhaust. It's the lightweight, universal heat problem-solver for virtually any motorcycle exhaust system. Backed by a Limited Lifetime Warranty.
From Warp 9, top of the line Adventure Pegs. a full 5" long and 2.5" wide will give your feet the perfect perch whether you are cruising down the highway or standing up hammering down a single track trail.
NOTE: These pegs DO NOT fit the '18 model!
