This is the maintenance schedule and associated service intervals for the Old Yamaha TW200 up until the year 2000.
I call it the “Old” Yamaha TW200 because that’s how people are likely to describe it. It had a kick starter and a few other unique attributes, and some of the parts were different.
But the old TW200 was largely similar to the new (2001+) TW200 in maintenance schedule, with a few items changing over only.
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Old Yamaha TW200 Maintenance Schedule
Below is the maintenance schedule for the old Yamaha TW200.
We’ve made it simpler, removing the “break-in” maintenance.
For higher odometer readings, repeat the pattern of the last two columns, adding 3000 miles (5000km).
Essentially the Yamaha TW200 has 3000 mile or 5000 km service intervals, or 6 month intervals. At every service, change the oil, clean the air filter, check the spark plug (or replace it), and check the valve clearances.
There are a host of other checks to do, too — see the schedule below.
|mi x 1000||3||6||9||12|
|km x 1000||5||10||15||20||Every|
|Engine oil — Warm-up engine before draining (Yamalube 10W40)||✓||✓||✓||✓||6 months|
|Oil filter — Replace filter element and clean oil strainer. Replace oil strainer if damaged. (KN143)||✓||✓||Year|
|Air filter — wash and damp with oil. (Yamalube foam air filter oil)||✓||✓||✓||✓||6 months|
|Check spark plug condition. Adjust gap and clean.|
Target gap: 0.6-07mm (0.02-0.03 in)
|Spark plug — Replace (NGK D8EA)||✓||✓||Year|
|Valve clearance — Check and adjust valve clearance when engine is cold.||✓||✓||✓||✓|
|Cam chain — Check and adjust chain tension.||✓||✓||✓||✓|
|Brakes — Adjust free play. Replace shoes if necessary.||✓||✓||✓||✓|
|Clutch — Adjust free play.||✓||✓||✓||✓|
|Chain — Check chain condition and drive chain slack. Adjust and lubricate chain thoroughly (with chain lubricant)|
Target slack: 30-40mm / 1.2-1.6 in free vertical movement)
Tighten axle nut to 90 Nm / 66 lb-ft
|500 km (300 mi) or 6 months|
|Control cables — Apply cable lubricant.||✓||✓||✓||✓||6 months|
|Rear arm pivot — Apply until new grease shows (Lithium soap-based grease.)||✓||✓||✓||✓||6 months|
|Brake / lever pivot — Lube with lithium soap-based grease.||✓||✓||✓||✓||6 months|
|Lubricate with lithium soap-based grease||✓||✓||✓||✓||6 months|
|Sidestand — Check operation and lubricate.||✓||✓||✓||✓|
|Front fork — Check operation and for leakage.||✓||✓||✓||✓|
|Steering bearings — Check for looseness. Moderately repack (R) with lithium soap-based grease.||✓||✓||R||✓|
|Wheel bearings — Check for smooth rotation. Replace if necessary.||✓||✓||✓||✓|
|Check specific gravity and voltage. Check that the breather pipe is working properly.||✓||✓||✓||✓|
|Sidestand switch — Check and clean or replace if necessary.||✓||✓||✓||✓|
|Check fuel hose for crack or damage.||✓||✓||Year|
|Check exhaust for leakage. Retighten and/or replace gaskets if necessary.||✓||✓||✓||✓|
|Clean spark arrester||✓||✓||✓||✓|
|Check and adjust engine idle speed.||✓||✓||✓||✓||6 months|
|Adjust throttle cable free play. (2-4mm)||✓||✓||✓||✓|
|Check evap control system for damage.||✓||✓|
Tire Sizes and Pressures
Regularly check the tires. If tread falls below 1mm (0.04 in), you need to change the tires. These are the tires (and also recommended tire pressure)
|Wheel||Tire size||Tire pressure (cold)|
|Front||130/80-18 66P||Up to 80 kg: 125 kPa / 18 psi|
80kg+: 150 kPa / 22 psi
Off-road: 125 kPa / 18 psi
|Rear||180/80-14 M/C 78P||Up to 80 kg: 125 kPa / 18 psi|
80kg+: 175 kPa / 25 psi
Off-road: 125 kPa / 18 psi
The TW200 takes a maximum load of 146 kg / 344 lb, including rider, cargo, passenger, and any accessories.
About the Old Yamaha TW200 (pre-2001)
The early Yamaha TW200 was the original and existed for decades unchanged.
The TW200 is a farm bike, mini adventurer, or everyday bike… it does a lot of things easily and with aplomb.
The TW200 is powered by a 196 cc four-stroke single-cylinder engine. It has a mild compression ratio of 9.5:1, air cooling, and a carburettor.
The final drive is via a 5-speed gearbox and a chain drive.
The beauty of the TW200 is its simplicity. It’s really a bike that’ll survive the apocalypse. You can be sure it’ll always be around, because it’s easy to repair with very few tools. And even with a small 1.8 US gallon tank (7 litres), you should be able to get over 150 miles or 220 km as it uses very little fuel.
From 2001 onward, only a few things changed in the maintenance schedule, but it’s still separated out — you can find it here.
Manual for the Old Yamaha TW200
The above information was gleaned from the owner’s manual for the old Yamaha TW200 (from the year 2000).
We compared it to previous years and didn’t find anything significant changed.
You can download it from Yamaha’s website here.