Motorcycles | Yamaha | Yamaha Dirt Bikes

Yamaha TW200 (2001+) Maintenance Schedule and Service Intervals

2018-2019 Yamaha TW 200

This is the maintenance schedule and associated service intervals for the Yamaha TW200 from 2001 onward — the “second gen”, updated from the first gen.

The TW200 is (or was) one of the last “farm bikes”. It was originally launched in 1987, and still available in some parts of the world, like the US, despite — or because of — its ancient design. In its over three decades of life, the only external change has been to remove a kickstarter, and to replace the front drum brake with a disc brake. The rear brake is still a disc brake.

2004 Yamaha TW 200
1998 Yamaha TW200

Since 2001, there have been some minor changes to the maintenance. For example, the 2001+ model has a spark arrester, and no longer requires cam chain to be inspected

2001+ Yamaha TW200 Maintenance Schedule

Below is the maintenance schedule for the Yamaha TW200.

The maintenance for the Yamaha TW200 is broken into two sections: periodic maintenance for emission control systems, and general maintenance and lubrication.

Periodic Maintenance Emission Control System

Tip

  • From 19000 mi (31000 km) or 36 months, repeat the maintenance intervals starting from 7000 mi (11000 km) 12 months.
  • Items marked with an asterisk require special tools, data and technical skills, have a Yamaha dealer perform the service — or do it yourself if you’re brave!
  • The air filter needs more frequent service if you are riding in unusually wet or dusty areas (which you probably will be, with this bike!)

Hydraulic brake system

  • When disassembling the master cylinder or caliper cylinder, always replace the brake fluid. Check the brake fluid level regularly and fill as required.
  • Replace the oil seals on the inner parts of the master cylinder and caliper cylinder every two years.
  • Replace the brake hoses every four years or if cracked or damaged.
ItemMiles60040007000100001300016000
KM1000600011000160002100026000
Months1612182430
Fuel line*•Check fuel hoses for cracks or damage, replace if necessary
Spark plug*•Check condition
Adjust gap and clean.
Replace regularly (R)
RR
Spark arrester*•Clean
Valve clearance*•Check and adjust valve clearance when engine is cold
Crankcase breather system* (if fitted)•Check breather hose for cracks and damage
•Replace if necessary
Idle speed*•Check and adjust engine idle speed
Exhaust system*•Check for leakage
•Tighten if necessary
•Replace gasket(s) if necessary.
Evaporative emission control system* (for California only)•Check control system for damage
•Replace if necessary
Yamaha TW200 periodic emission maintenance

General Maintenance and Lubrication Chart

ItemMiles60040007000100001300016000
KM1000600011000160002100026000
Months1612182430
Air filter element*•Clean with solvent.
•Wet filter must be washed and damped with oil (Yamaha foam air filter oil)
•Replace if necessary.
Battery*•Check specific gravity and breather hose for proper operation.
Clutch*•Check operation.
•Adjust or replace cable.
Front brake*•Check operation, fluid level, and for fluid leakage.
•Adjust break lever free play and replace brake pads if necessary
Rear brake*•Check operation.
•Adjust cable and replace brake shoes if necessary.
Brake hose*•Check for cracks or damage.
•Check for correct routing and clamping
•Replace (every 4 years)
Brake fluid*•Change (every 2 years)
Wheels*•Check runout, spoke tightness and for damage.
•Tighten spokes if necessary.
Tires*•Check tread depth and for damage.
•Replace if necessary.
•Check air pressure.
•Correct if necessary.
Wheel bearings*•Check bearings for smooth operation.
•Replace if necessary.
Swingarm pivot
bushes*
•Check bush assemblies for looseness.
•Apply lithium-soap-based grease.
Drive chain*•Check chain slack/alignment and condition.
•Adjust and thoroughly lubricate chain with chain lubricant.
Every 300 mi (500 km) and after washing the motorcycle or riding in the rain or wet areas
Steering bearings*•Check bearing assembly for looseness.
•Moderately repack with lithium-soap-based grease every 10000 mi (16000 km) or 18 months.
Repack
Chassis fasteners*•Check all chassis fitting and fasteners.
•Correct if necessary.
Brake lever pivot shaft•Apply silicone grease lightly
Brake pedal pivot shaft•Apply lithium-soap-based grease lightly.




Clutch lever pivot shaftApply silicone grease lightly




Sidestand pivot•Check operation.
•Apply lithium-soap-based grease lightly.





Sidestand switch*•Check operation and replace if necessary.





Front fork*•Check operation and for oil leakage.
•Replace if necessary.





Shock absorber assembly*•Check operation and for oil leakage.
•Replace if necessary.





Engine oil•Change (warm engine before draining).





Oil filter•Clean and check. Replace if damaged.


Engine oil strainer•Clean and check. Replace if damaged.


Front and rear brake switches*•Check operation.





Control and meter cables*•Apply Yamaha chain and cable lubricant or other suitable cable lubricant thoroughly





Throttle grip housing and cable*•Check operation and free play.
•Adjust the throttle grip free play, and adjust if necessary
•Lubricate the throttle grip housing





Lights, signals and switches*•Check operation.
•Adjust headlight beam.






Yamaha TW200 regular maintenance schedule

About the Yamaha TW200

The TW200 is a very versatile motorcycle. It is powered by a 196cc air-cooled SOHC 2-valve 4-stroke single with plenty of low-and mid-range torque.

It has a low seat and fat tyres that give it a very smooth ride over a wide variety of terrain. Whether you’re a beginner rider, a veteran, a camper, or a citt commuter, this bike has a use.

Manual for the Yamaha TW200

2018-2019 Yamaha TW200 Maintenance schedule screenshot from manual
Maintenance schedule from 2018 TW200 manual
Maintenance schedule from 2001 Yamaha TW200
Maintenance schedule from 2001 Yamaha TW200

The above information was gleaned from the owner’s manual for the Yamaha TW 200.

You can download it from Yamaha’s website here.

Similar Posts