Yamaha Tri-Moto 200 (YTM200K) Service Manual – 1986 (P/N LIT-11616-03-83)

This Yamaha factory service manual covers the 1986 Tri-Moto 200 (YTM200K), P/N LIT-11616-03-83. The identification section shows where to find the frame and engine stamps so you can match the three-wheeler to the manual before starting work.

PDF Bookmarks and Wiring Detail

Navigation and diagram detail — Embedded bookmarks jump to the index, all seven chapters, and the full wiring diagram. The PDF has no text search. Zoom in to read the smaller wire color codes and switch labels.

The download is one printable English PDF with 128 pages, including the original cover, Yamaha’s notice, the index, and the appendices.

Engine Overhaul, Drivetrain Repair, and Electrical Tests

These selected topics show the scope of the manual. The periodic service chapter also covers air filter care and headlight beam adjustment.

• Scheduled service — Maintenance and lubrication charts, valve and decompression adjustments, cam-chain and drive-chain tension, ignition timing, and compression testing.
• Engine overhaul — Engine removal and installation, cylinder head and valve service, piston and cylinder inspection, crankshaft and connecting rod checks, and recoil starter repair.
• Clutches and transmission — Primary and secondary clutch removal, inspection, and adjustment, plus internal transmission checks and reassembly.
• Carburetor service — Mikuni VM22 disassembly and cleaning, jet and float valve inspection, and fuel-level checking and adjustment.
• Brakes, wheels, and steering — Front drum and cable-operated rear disc brake service, wheel bearings, rear axle, front fork, steering head, and cable maintenance.
• Electrical diagnosis — Magneto and ignition coil resistance checks, spark-gap testing, AC lighting output, stop and dimmer switch continuity, and a full wiring diagram.

Yamaha wrote the manual primarily for its dealers and qualified mechanics. It assumes familiarity with basic mechanical service and repair procedures.

Cylinder Head and Engine Reassembly

The cylinder and flywheel magneto can be removed with the engine in the frame. Clutch removal requires taking off the right rear wheel. These access notes help determine how much disassembly a job requires.

Cylinder head work includes valve guide replacement and reaming, valve seat cutting and lapping, and inspection of the valve stems and guides. Yamaha calls for replacing the valve, guide, and seal if the valve stem end has mushroomed.

The overhaul chapter also covers wet-sump oil pump rotor inspection, bearing and oil seal replacement, crankcase sealing, piston ring positioning, and alignment of the balancer and cam timing marks. After an oil change, Yamaha calls for checking flow at the cylinder head oil gallery because loss of oil flow can seize the engine.

Transmission, Axle, and Fork Service

Transmission inspection covers gear engagement dogs, shaft runout, shift forks, the guide bar, and shift cam grooves. The manual identifies which pinions require a press fit and shows how to orient the shift forks during assembly.

Chassis procedures cover rear axle runout, chain and sprocket wear, brake lining and pad inspection, and fork tube and spring checks, seal replacement, and refilling. Yamaha specifies secure support for wheel and fork work, a drag check after rear brake adjustment, and new cotter pins and lock washers at the designated axle and sprocket fasteners.

Factory Tools and Reference Drawings

The special-tool list identifies the valve spring compressor YM-04019, universal puller YU-33270 with flywheel attachment YM-33278, crankshaft installer YU-90050, steering ring-nut wrench YU-01268, and fork seal installer collar YM-33281 and weight YM-08010.

The appendix contains 12 exploded assembly views, two lubrication diagrams, cable-routing sheets, and tables for torque, capacities, clearances, wear limits, and electrical tests. In the electrical chapter, the spark-gap test helps narrow down a weak-spark or misfire complaint before individual coil and winding checks.

Sample Valve Clearances and Clutch Wear Limits

At top dead center on the compression stroke with the engine cold, the specified valve clearance is 0.05–0.09 mm on the intake and 0.11–0.15 mm on the exhaust.

The clutch inspection gives separate wear limits of 2.5 mm for the primary clutch shoes and 2.8 mm for the secondary clutch friction plates.