Yamaha · Yamaha four-stroke single (XT/TT/SR 500 1976-)

TW200

Library entry covers 1987-2026

18 factory 39 guideline

Published source

Yamaha TW200 Owner's Manual (Yamaha Motor Co.), Periodic Maintenance Charts pp.6-3 to 6-5

Factory owner's handbook. Covers TW200 owner's manual (US, 2001-2006 generation), chart in mi, km and months.

Open the source

57 items for a 2002 model, grouped by interval the way a factory chart is laid out.

How this bike is built (what the schedule is based on)

Engine cycle: Four-stroke
Engine lubrication: Wet sump (oil in crankcase)
Oil filtration: Mesh screens / strainers only
Valve gear: Overhead cam, screw/locknut adjusters
Ignition: Magneto (incl. magdyno, flywheel magneto)
Charging: Alternator / stator with rectifier
Battery: Wet cell (flooded lead-acid, needs topping up)
Fuel system: Single carburetor
Cooling: Air / oil cooled
Primary drive: Gear or chain inside engine, shares engine oil
Gearbox oil: Shares engine oil
Clutch control: Hand lever, cable
Final drive: Chain
Front suspension: Telescopic fork
Rear suspension: Swingarm, twin shocks
Front brake: Drum (or band / stirrup)
Rear brake: Drum (or band / belt rim)
Wheels: Spoked, tubed
Sidecar: No sidecar

Maintenance schedule

2002 Yamaha TW200

On the road: every 200 mi

1 item

Check engine oil level

Pre-ride / on the road

Guideline

Each fuel stop on old machines. Dry sump: check the tank hot, engine idling or just stopped, per your manual.

On the road: every 300 mi

3 items

Check lights, horn, brake light switches

Pre-ride / on the road

Guideline
Check tire pressures

Pre-ride / on the road

Guideline
Lubricate drive chain

Pre-ride / on the road

Factory

Manual: Drive chain: check, adjust and lubricate. Factory: Periodic maintenance charts pp.6-3 to 6-5: every 300 mi (500 km); special O-ring chain lubricant

On the road: every 600 mi

1 item

Check chain slack and rear wheel alignment

Pre-ride / on the road

Guideline

Every 1,000 mi or 6 months

3 items

Adjust front drum brake

Brakes

Guideline
Adjust rear drum brake and rod / cable linkage

Brakes

Guideline
Inspect tire tread, sidewalls and date codes

Wheels and tires

Guideline

Every 3,000 mi or 6 months

12 items

Change engine oil

Engine

Factory

Manual: Engine oil: change. Factory: Periodic maintenance charts pp.6-3 to 6-5: first at 600 mi (1,000 km)
Check and adjust valve clearances

Engine

Factory

Manual: Valve clearance: check and adjust. Factory: Periodic maintenance charts pp.6-3 to 6-5: dealer item; engine cold; first at 600 mi (1,000 km)
Clean / inspect air filter

Fuel and air

Factory

Manual: Air filter (wet foam): wash and oil. Factory: Periodic maintenance charts pp.6-3 to 6-5: dealer item
Synchronize carburetors

Fuel and air

Factory

Manual: Idle speed and cable free play: adjust. Factory: Periodic maintenance charts pp.6-3 to 6-5: dealer item; exhaust system checked and spark arrester cleaned at the same interval
Check battery electrolyte, top up with distilled water

Ignition and electrics

Factory

Manual: Battery: check specific gravity and breather. Factory: Periodic maintenance charts pp.6-3 to 6-5
Adjust clutch free play, lubricate cable and lever pivot

Primary and gearbox

Factory

Manual: Clutch: adjust free play. Factory: Periodic maintenance charts pp.6-3 to 6-5: dealer item; first at 600 mi
Grease and check center / side stand and springs

Rear suspension and frame

Factory

Manual: Sidestand switch: check. Factory: Periodic maintenance charts pp.6-3 to 6-5: dealer item; first at 600 mi
Grease swingarm pivot

Rear suspension and frame

Factory

Manual: Rear arm pivot shaft: grease. Factory: Periodic maintenance charts pp.6-3 to 6-5: dealer item
Inspect rear shocks for leaks and damping

Rear suspension and frame

Factory

Manual: Front fork: check operation and leakage. Factory: Periodic maintenance charts pp.6-3 to 6-5: dealer item
Check brake pads and discs

Brakes

Factory

Manual: Brake system: adjust free play, check pads and shoes. Factory: Periodic maintenance charts pp.6-3 to 6-5: dealer item; first at 600 mi
Check wheel bearings for play

Wheels and tires

Factory

Manual: Wheel bearings: check. Factory: Periodic maintenance charts pp.6-3 to 6-5: dealer item
Lubricate control cables and lever pivots

Controls and cables

Factory

Manual: Control and meter cables: lubricate. Factory: Periodic maintenance charts pp.6-3 to 6-5: first at 600 mi; lever pivots, pedal shafts and sidestand pivots every 3,000 mi

Every 3,000 mi or 12 months

9 items

Check throttle cable(s) free play and return

Fuel and air

Guideline
Clean fuel tap filter / sediment bowl

Fuel and air

Guideline
Check / set ignition timing

Ignition and electrics

Guideline
Clean and gap contact breaker points, oil cam felt

Ignition and electrics

Guideline
Clean drive chain thoroughly (remove and soak, re-lube)

Final drive

Guideline

Non O-ring chains on old machines: remove, clean, soak in hot chain grease or lube, refit with the master link clip closed end leading.
Inspect chain and sprockets for wear (measure stretch)

Final drive

Guideline
Inspect fork seals, stanchions and fork boots

Front end

Guideline
Check footrests, pegs, rear brake and gear lever pivots

Rear suspension and frame

Guideline
Check spoke tension and wheel true

Wheels and tires

Guideline

Every 4,000 mi or 12 months

1 item

Lubricate brake cam spindles, check linings and drums

Brakes

Guideline

Every 6,000 mi or 12 months

8 items

Clean oil strainers / mesh screens

Engine

Factory

Manual: Oil filter element and strainer: clean. Factory: Periodic maintenance charts pp.6-3 to 6-5: dealer item; first at 600 mi; replace if damaged
Inspect, clean and gap spark plugs

Engine

Factory

Manual: Spark plug: check, gap and clean. Factory: Periodic maintenance charts pp.6-3 to 6-5: at 4,000 and 10,000 mi
Replace spark plugs

Engine

Factory

Manual: Spark plug: replace. Factory: Periodic maintenance charts pp.6-3 to 6-5: first at 7,000 mi (11,000 km)
Clean carburetor float bowl(s), check float level and jets

Fuel and air

Guideline

Ethanol fuel varnishes old carbs quickly in storage.
Replace fuel lines

Fuel and air

Factory

Manual: Fuel hose: check. Factory: Periodic maintenance charts pp.6-3 to 6-5: dealer item
Check charging voltage and regulator / cut-out

Ignition and electrics

Guideline
Check swingarm bushes for play

Rear suspension and frame

Guideline
Lubricate speedometer / tachometer cables, check drive

Controls and cables

Guideline

A dry speedo cable whips the needle and eventually kills the instrument.

Every 6,000 mi or 2 years

2 items

Lubricate and check automatic advance unit

Ignition and electrics

Guideline
Magneto: clean slip ring and pickup brush, check HT lead

Ignition and electrics

Guideline

Every 10,000 mi or 18 months

1 item

Check steering head bearing adjustment

Front end

Factory

Manual: Steering bearings: repack. Factory: Periodic maintenance charts pp.6-3 to 6-5: dealer item; check every 3,000 mi

Every 10,000 mi or 2 years

1 item

Compression test (or leak-down)

Engine

Guideline

Every 12,000 mi or 2 years

1 item

Replace air filter element

Fuel and air

Guideline

Every 12,000 mi or 3 years

1 item

Replace points and condenser

Ignition and electrics

Guideline

Every 15,000 mi or 3 years

1 item

Change fork oil

Front end

Guideline

Some early telescopic forks are grease filled or use very small oil quantities. Check your manual.

Every 15,000 mi

1 item

Replace brake linings / skim drums (wear based)

Brakes

Guideline

Every 18,000 mi

1 item

Replace chain and sprockets (wear based)

Final drive

Guideline

Every 20,000 mi or 4 years

2 items

Repack / replace steering head bearings

Front end

Guideline

Many old machines use loose balls in cups and cones. Taper roller conversions are common.
Repack / replace wheel bearings

Wheels and tires

Guideline

Cup-and-cone and taper roller hubs need periodic repacking and adjustment.

Every 25,000 mi or 6 years

1 item

Replace swingarm bushes / bearings

Rear suspension and frame

Guideline

Every 25,000 mi or 10 years

1 item

Magneto overhaul / re-magnetize, replace capacitor

Ignition and electrics

Guideline

Weak spark when hot is the classic symptom. Old capacitors fail with age, not miles.

Every 30,000 mi or 6 years

1 item

Rebuild forks: seals, bushes, springs

Front end

Guideline

Every 6 months

1 item

Clean battery terminals, check charge and strap

Ignition and electrics

Guideline

Every 2 years

2 items

Inspect wiring, bullet connectors and ground points

Ignition and electrics

Guideline
Inspect frame, welds and lugs for cracks

Rear suspension and frame

Guideline

Every 6 years

2 items

Replace inner tubes and rim tape with tires

Wheels and tires

Guideline
Replace tires on age (regardless of tread)

Wheels and tires

Guideline

Guideline lines: Intervals here are general guidelines for the machine's era and layout, compiled for this app. They are not factory manual figures. Check your workshop manual, and edit any interval in the bike's Schedule tab.