How to Change Coolant in a 1996 Yamaha TW200
Shop parts for a 1996 Yamaha TW200 Dirt Bike.
Keeping your 1996 Yamaha TW200’s cooling system in peak form isn’t just about preventing overheating—it protects engine performance and longevity, especially for this legendary air-cooled, lightweight dual-sport model. Though the TW200 is famed for its simplicity, many overlook that certain later models feature an auxiliary oil cooler circuit, making the draining and replenishing process even more important to ensuring reliability.
Before You Begin
- Readiness: Make sure the engine is completely cool before starting to prevent burns from hot coolant or oil. Place the bike on a stable, level surface.
- Supplies: You’ll need a drain pan, socket set, screwdrivers, fresh motorcycle coolant, and distilled water (if flushing). Consult your owner’s manual for exact coolant specification and capacity.
- Additional Note: Although many TW200s are air-cooled, if your model incorporates a factory or aftermarket oil cooler system, the circuit acts in a manner similar to traditional liquid cooling and requires periodic changing or flushing for best performance. Always double-check your model’s configuration before proceeding.
Step-by-Step Coolant Change Guide
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Remove Old Coolant
Locate and remove the radiator cap or oil cooler circuit reservoir cap. (If your TW200 does not use a liquid coolant system, skip to periodic oil and fin cleaning procedures.) Place the drain pan below the drain bolt (usually at the lowest point of the system, typically on the side or bottom of the cooler housing). Loosen the drain bolt and let old coolant flow completely into your pan. -
Flush the System (Recommended for neglected cooling circuits)
After draining, reinstall the drain bolt snugly. Fill the circuit with distilled water, replace the cap, and run the engine just long enough for the thermostat to open (do not let it overheat). Turn the engine off, let cool, and drain the distilled water completely. Repeat until the drained water runs clear. This step can be skipped if you maintain the system regularly. -
Refill With Fresh Coolant
Tighten the drain bolt to the recommended torque spec. Using a funnel, slowly pour the new coolant (Yamaha-approved or high-quality motorcycle coolant) into the filler opening until full. Squeeze any rubber hoses gently and tip the bike side to side to help release trapped air bubbles. -
Burp the System
Start the engine with the cap off and let it idle–you’ll see air bubbles rise as the coolant circulates. Blip the throttle a few times and continue until bubbling ceases. Add more coolant if needed, keeping the level to the filler neck. -
Final Steps
Replace and tighten the cap. Check the coolant reservoir or cooler level and top off as needed. Wipe any spilled fluids, dispose of old coolant responsibly, and inspect for leaks.
Additional Tips for 1996 TW200 Owners
- Air-Cooled Simplicity: Most TW200s of this era use air-cooling, so if yours lacks an auxiliary oil cooler, routine fin cleaning is even more critical. Gently remove dirt and debris from engine cooling fins for optimal performance.
- Auxiliary Oil Cooler Models: These require coolant-style maintenance. Check all related lines and connections for leaks with every coolant change.
- After Service: Ride for several miles and recheck coolant/oil cooler levels, topping off as needed. Double-check drain and filler bolts for tightness after first heat cycle.
The 1996 Yamaha TW200 is celebrated for reliability and ruggedness—regular coolant (or oil cooler circuit) changes are the secret to keeping yours trail-ready 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.