Yamaha TW200 (Gen 1, pre-2001) Maintenance Schedule and Service Intervals

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.

1998 Yamaha TW200

Old Yamaha TW200 Maintenance Schedule

Below is the maintenance schedule for the old Yamaha TW200.

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

Items marked with a * are slightly more complicated and require special tools and knowledge. Yamaha recommends getting a dealer to do them.

For higher odometer readings, repeat the pattern of the last two columns, adding 3000 miles (5000km).

Periodic Maintenance Emission Control System

Cam chain*•Check and adjust chain tension.
Valve clearance*• Check and adjust valve clearance when engine is cold.
Spark plug*• Check condition.
• Adjust gap and clean.
• Replace at 11,000 km (or 12 months) and thereafter every 10,000 km (or 12 months).
Fuel line*•Check fuel hose for crack or damage.
•Replace if necessary.
Exhaust system*•Check for leakage
•Retighten if necessary.
•Replace gaskets if necessary.
Spark arrester• Clean
Idle speed*•Check and adjust engine idle speed.
• Adjust cable free play.
Evaporative emission control system* (California only)•Check control system for damage.
•Replace if necessary.
Regular emissions emissions maintenance for the Yamaha TW200

General Maintenance and Lubrication Chart

Engine Oil• Warm-up engine before draining (Yamalube 10W40 or Yamalube 10W50)
Oil filter/Strainer*• Replace filter element and clean oil strainer.
• Replace oil strainer if damaged.
Air Filter*• Wet type filter must be washed and damped with oil. (Yamalube foam air filter oil)
Brake system*• Adjust free play.
• Replace shoes if necessary.
Clutch*• Adjust free play.
Drive chain• Check chain condition.
• Adjust and lubricate chain thoroughly (with chain lubricant)
Every 500 km (300 mi)
Control and meter table• Apply chain lube thoroughly (with cable lubricant)
Rear arm pivot shaft*• Apply until new grease shows (Lithium soap-based grease.)
Brake/ Clutch lever pivot shaft• Apply chain lube lightly (cable lubricant)
Brake pedal and shift pedal shaft• Lubricate
• Apply chain lube lightly (cable lubricant)
Sidestand pivots and kick crank boss*• Check operation and lubricate.
• Apply cable lubricant.
Front fork*• Check operation and for leakage.
Steering bearings*• Check bearing assembly for looseness.
• Moderately repack every 10,000 mi (16,000 km) with lithium soap-based grease.
Wheel bearings*• Check bearings for smooth rotation.
Battery• Check specific gravity.
• Check that the breather pipe is working properly.
• Correct if necessary.
Sidestand switch*• Check and clean or replace if necessary.
Regular maintenance for the old Yamaha TW200

About the Old Yamaha TW200

The TW200’s strong-pulling 196cc four-stroke single-cylinder engine with built-in counterbalancer delivers predictable power with little vibration.

From 2001 onward, only a few things changed in the maintenance schedule.

Manual for the Old Yamaha TW200

2000 Yamaha TW200 Maintenance schedule screenshot from manual

The above information was gleaned from the owner’s manual for the old Yamaha TW200 (from the year 2000).

You can download it from Yamaha’s website here.

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