How to Change the Oil in a 1991 Yamaha TW200

Shop parts for a 1991 Yamaha TW200 Dirt Bike.

Doing an oil change on your 1991 Yamaha TW200 is critical for ensuring longevity & reliable performance. Below is a detailed, step-by-step guide tailored specifically to this model, including all the tools required and model-specific notes every TW200 owner should know.

Tools & Supplies Needed

  • 10mm and 12mm socket or wrench
  • Oil drain pan
  • Funnel
  • Clean rags or paper towels
  • New oil filter OR cleanable strainer (Yamaha OEM recommended)
  • Replacement O-rings for the oil drain bolt and oil filter cover (recommended)
  • Screwdriver
  • Torque wrench
  • 1 quart (1 liter) of 10W-40 motorcycle engine oil (check your owner's manual for specifics)
  • Gloves (optional, but keeps hands clean)

Important Callouts for the 1991 Yamaha TW200

  • Oil Capacity:– The TW200 uses just about 1 liter of oil, do not overfill.
  • Sight Glass:– This model uses a sight glass to check the oil level; ensure the bike is upright and level for an accurate reading.
  • O-ring replacement is recommended every oil change to prevent leaks.
  • If reusing the oil filter strainer, clean thoroughly and inspect for tears or damage (a must for a 1991 bike).
  • Torque Spec:– Tighten the oil drain bolt to 43 Nm (per original spec sheet). Be careful not to overtighten and strip the threads.
  • Always ensure the new (or cleaned) oil filter has the correct number and placement of oil flow holes to maintain top-end lubrication.

Step-By-Step Oil Change Instructions

  1. Start and Warm Up the Engine
    • Let the bike idle for about 5 minutes. This thins the oil and allows more old oil to drain out.
  2. Stabilize the Motorcycle
    • Use a center stand, paddock stand, or have someone hold the bike vertical and steady.
  3. Remove the Skid Plate (if equipped)
    • Use your socket or wrench to remove the skid plate bolts and set the plate aside.
  4. Drain the Oil
    • Place your oil drain pan beneath the engine's drain bolt (on the bottom left side of the crankcase).
    • Loosen and remove the drain bolt with a 12mm socket or wrench. Watch out for hot oil.
    • If present, remove the oil strainer, spring, and O-ring along with the drain bolt.
  5. Clean and Inspect the Oil Strainer
    • Spray the strainer with brake cleaner or use a clean rag. Inspect for debris or damage.
    • If the O-ring looks worn or deformed, replace it before reinstallation.
  6. Replace the Oil Filter
    • Remove the oil filter cover using a 10mm socket or screwdriver (typically three bolts).
    • Take out the old filter. Inspect and, if needed, replace the cover O-ring.
    • Insert the new or cleaned oil filter, ensuring that all necessary oil flow holes are present and oriented correctly.
    • Reinstall the filter cover and tighten the screws to snug, but avoid overtightening (use a cross pattern if applicable).
  7. Reinstall the Drain Bolt and Strainer
    • Insert the clean strainer and new O-ring, followed by the drain bolt. Hand-tighten, then tighten to 43 Nm using your torque wrench.
  8. Refill with Oil
    • Unscrew the oil filler cap on the right side of the engine.
    • Place a funnel in the filler opening and add about 0.9–1.0 liter of 10W-40 motorcycle oil.
    • Replace and hand-tighten the oil filler cap.
  9. Start and Circulate the Oil
    • Start the bike and let it idle for about one minute (do not rev).
    • Turn off the bike, let it sit for another minute to allow the oil to settle.
  10. Check Oil Level
    • Hold the bike upright and check the oil sight glass (right side of the crankcase). The oil should be between the sight glass' upper and lower lines.
    • If necessary, add oil in small increments to reach the right level.
  11. Reinstall the Skid Plate
    • Align and bolt the skid plate back in place before your next ride.
  12. Dispose of Old Oil Properly
    • Take the used oil and filter to a proper disposal or recycling facility.

Final Check and Start-Up

  • Give everything a once-over for leaks, especially around the drain bolt, oil filter cover, and filler cap.
  • Check your oil level again after your first short ride, adjust as needed.

Your 1991 Yamaha TW200 oil change is complete. Routine oil changes are an easy way to extend the engine life and keep the legendary TW200 running smoothly, both on and off the trail. For Yamaha-approved parts, oil, O-rings, and filters, visit MotoSport.com and get everything you need delivered fast.

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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.