How to Change the Coolant in a 1991 Yamaha TW200
Shop parts for a 1991 Yamaha TW200 Dirt Bike.
Routine coolant changes help keep your 1991 Yamaha TW200 running cool and reliable on the trails. Unlike air-cooled models, the TW200 from this era relies on a liquid cooling system that demands proper maintenance. Below is a step-by-step, MotoSport-exclusive procedure tailored to this legendary dual-purpose machine.
Before You Start
- Make sure your engine is completely cool before working on the cooling system. Opening the radiator cap on a hot engine can cause serious injury.
- Prepare a drain pan, socket wrench, funnel, clean rags, and the correct fresh coolant (consult your owner's manual for volume and specification).
- Use only distilled water to mix with concentrated coolant–never tap water–to protect vital components from mineral buildup.
Step-by-Step Coolant Change on the 1991 Yamaha TW200
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Access the Radiator and Drain Bolt
Remove any protective bodywork or panels blocking access to the radiator. Locate the radiator cap at the highest point of the system, and the coolant drain bolt on the engine side cover or lower radiator tank. -
Remove the Radiator Cap
With the bike cold and upright, slowly remove the radiator cap to relieve system pressure. This allows old coolant to drain completely. -
Drain the Old Coolant
Position the drain pan under the bike. Use a socket wrench to remove the coolant drain bolt (and sealing washer). Let the coolant flow out until it's fully drained. Removing the bolt from the bottom of the water pump cover on the TW200 is typically required for complete drainage. -
Flush the Cooling System (Optional but Recommended)
Replace the drain bolt and torque to spec. Pour distilled water into the radiator, then run the engine briefly with the radiator cap off. Shut down, remove the drain bolt again, and drain. Repeat until the water runs clear. -
Replace Sealing Washers
Install a new sealing washer on the drain bolt if needed to prevent leaks, then reinstall and torque the bolt. -
Refill with Fresh Coolant
Slowly pour the new coolant mix into the radiator up to the base of the filler neck. Fill the overflow reservoir (if equipped) to the "full" line. -
Burp the System
With the radiator cap still off, start the engine and let it idle. Rev gently and rock the bike to help release air bubbles. Let the bike warm up until the thermostat opens. Top off coolant as needed. -
Check for Leaks & Final Top-Off
Shut down the engine, let it cool, and recheck the coolant level. Add more coolant if needed to ensure it's filled to the base of the radiator neck and the reservoir is at the full mark. -
Reinstall the Radiator Cap and Bodywork
Securely reinstall the radiator cap and any bodywork removed earlier. -
Proper Disposal
Dispose of the old coolant responsibly at a local auto parts store or recycling center. Never pour it down the drain or on the ground.
TW200-Specific Tips & Considerations
- The TW200 is renowned for its wide, ATV-like tires and beginner-friendly manners, but overheating can lead to expensive repairs. Regular coolant changes (every two years or as stated in the manual) help prevent corrosion and prolong water pump life.
- On older TW200s, inspect hoses, clamps, and the radiator cap for signs of wear or leaks during every coolant service.
- The system is simple but can be prone to trapping air–if you notice fluctuating coolant levels or overheating, repeat the burping process to remove trapped air.
Proper cooling system care is key to enjoying your 1991 Yamaha TW200 on any terrain for years to come.
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Disclaimer: This guide is provided for general informational purposes only and is not intended to replace your motorcycle's official owner's manual. Always refer to your manufacturer's documentation for model-specific instructions, torque specifications, safety procedures, and maintenance requirements. If you are unsure or inexperienced, consider seeking assistance from a qualified mechanic or technician.