This PATENT PENDING kit converts your TW200 into a mountain goat! Massive traction! No tubes! No spokes!
Features: More traction. More Flex. More tire choices. Allows the use of a common, spoke free, tubeless, ATV wheel and tire. No more demounting to fix a flat. Over 10 years of testing in this kit.
Includes: Complete rear axle/hub assembly including OEM size bearings. Zinc plated. Mounting hardware included with complete installation instructions. Uses stock sprockets, brake drum, bearings and seals. Tire and wheel not included with hub only kit. (Requires the use of ITP Delta Steel Wheel 1422320014B or 1225579014 or comparable, available for purchase with kit.) Comes with installation instructions.
Required Wheel specs: 12x7, 4+3, 4/156 or 14x7, 4+3, 4/156. Stock polaris front wheels will not fit due to incorrect offset. Requires ITP Delta Steel Wheel 1422320014B or 1225579014 or comparable. (Not included in hub only kit)
Tire options: (Not includedin hub only kit) 25x8-12 or 25x8-14 are recommended. 26x9-12 or 26x9-14 will fit with extremely close tolerances. Tires with lugs on the sidewall will not clear the chain. This kit was designed around the Maxxis BigHorn style tire or comparable. For general usage we highly recommend the 25” tire on the 12” wheel setup. It handles much better. For extreme offroad usage the 26” setup may be more desirable. For the 26” setup your chain adjuster must be at least to the “5” on the adjustment cam. If your chain is new and is adjusted anywhere from the 1 to the third bump past the 4, the tire will be too far forward in the swingarm and the tire will rub.
Requires the removal of the inner chain cover bracket from the swingarm. (it's easy)
Requires trimming of the plastic chain guard. Different tire combinations may require additional clearancing on the swingarm.
Fits all years of Yamaha TW200, 87-present.
NOT DOT approved for highway usage.
PATENT PENDING
Yamaha TW200 ATV Fat Tire Conversion Rear Hub Only Kit
Yamaha TW200 Mountain Goat Fat Tire Conversion Kit Installation Instructions
Required tools: Normal metric hand tools for removal of rear wheel ,chain, brakes, etc. A motorcycle/atv style lift is also necessary. Removal of the rear axle bearing to retrieve the OEM axle bearing spacer is a bear. You will need a blind bearing puller or equivalent. If you do not wish to tackle this, you can order part number 90560-17305-00 from Yamaha. It’s $12.
Required parts: Rear hub/axle conversion kit, ITP Delta Steel Wheel 1422320014B or 1225579014 or comparable, and one of the following tire options; 25x8-12 or 25x8-14 are recommended. 26x9-12 or 26x9-14 will fit with extremely close tolerances. Tires with lugs on the sidewall will not clear the chain. This kit was designed around the Maxxis BigHorn style tire or comparable. For general usage we highly recommend the 25” tire on the 12” wheel setup. It handles much better. For extreme offroad usage the 26” setup is more desirable. NOTE: For the 26” setup your chain adjuster must be at least to the number 5 on the adjustment cam. If your chain is new and is adjusted anywhere from the number 1 to the third bump past the 4, the tire will be too far forward in the swingarm and the tire will rub.
Use the factory Yamaha service manual for instructions on removing and/or installing any and all factory parts on your TW. Refer to all safety precautions and fastener torque specs for safe and proper installation.
Step 1: Lift rear tire off the ground and secure motorcycle to prevent falling.
Step 2: Remove rear axle nut (22mm). Loosen chain adjuster cams. Remove rear brake rod wing nut. Remove top chain cover (8mm). Slide axle forward and roll chain off of rear sprocket. Remove rear axle and wheel assembly from the motorcycle. Keep up with the axle spacers on both sides of the rear axle assembly. Slide out the brake shoe assembly from the brake drum. NOTE: This is when you will need to decide if you want to tackle the OEM bearing spacer from the OEM axle/hub or just order a new one. The Yamaha part number is 90560-17305-00. You will be required to remove the axle bearing on the brake drum side of the assembly and slide the spacer out. Removing this bearing is the hardest part of this job. A blind bearing puller works best for this application.
Step 3: Using a saw blade or grinding wheel, completely remove the lower chain guard bracket from the lower left inside of the swingarm. Use all safety precautions when doing this. Touch up with silver paint if desired. Next, remove the rear bolt (10mm) from the rear lower outer chain guide and place the 2 supplied washers under the bolt head, then reinstall.
Step 4: Carefully remove the sprocket side axle bearing seal from the OEM axle tube (small pry bar). This can be reused if desired in the new axle. Remove the rear drive sprocket (14mm). Remove the rear brake drum assembly from the OEM axle assembly (12mm). At this point you will need to install the supplied axle bearings and axle spacer. Make sure to use the proper installation method to prevent bearing damage and don't forget the bearing spacer. Two bearings in the sprocket side, one in the brake drum side. Reinstall sprocket side axle seal.
Step 5: Using the OEM hardware, secure the rear brake drum to the new axle/hub. Torque to factory spec.
Step 6: Slide new steel wheel/tire over the sprocket side of the axle/hub with the valve stem facing the sprocket side of the assembly. Secure with the supplied ⅜” carriage bolts and flange nuts. The nuts should be on the valve stem side of the wheel with the carriage bolt entering through the brake drum side of the wheel hub flange. Tighten to 20 ft-lbs.
Step 7: Reinstall rear sprocket onto the axle assembly using the OEM hardware and torque specs. Install left axle bearing seal into axle assembly. Reinstall brake shoe assembly into the right side of the axle. Reinstall both axle bearing spacers. Install new complete assembly into the motorcycle. Roll the chain onto the sprocket and adjust the chain as required. Tighten the axle nut to proper torque spec. Reinstall brake rod into brake arm and adjust wing nut as required.
Step 8: Make the necessary adjustments to trim/fit the OEM chain guard over the chain and install. Double check your work, lube the chain, and take it for a test drive!
DISCLAIMER: COVINGTON MOTOR GROUP INC. WILL NOT BE LIABLE FOR ANY INCIDENTAL, CONSEQUENTIAL, OR SPECIAL DAMAGES AND/OR EXPENSES IN CONNECTION WITH THE PURCHASE OR USE OF THIS PRODUCT.
Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation(s) or exclusion(s) may not apply to you. NOT DOT approved for highway usage.
Covington Motor Group inc. 875 Lawrence st. Batesville, AR 72501