Yamaha TW200.. the swamp donkey

[Hurco550]

I haven't forgotten nor given up on this old steed, just got stalled for a bit. My wife and I are expecting our first child (due date is just a couple weeks away) and my better half seemed to think that "Getting the baby room ready" and "buying stuff for the baby" is more important than "Getting ANOTHER motorcycle running" and "buying MORE motorcycle parts" lol. If we're being honest she is a freaking champ and I'm lucky to have her to keep me grounded.

I did however buy a feebay special chunk-o-stainless mandrel bent exhaust tubing to mate up the head pipe to the rad little supertrapp. Once I get that fabbed up with all manner of pie cuts and what not, the carb and air box mounted and a simplified wire harness, I should see if the ol girl will breathe fire again.

Progress on all projects will likely be slower (than the already snail pace) from now on, but I will get out to the garage and tinker away in the moments that I can.

 

[cbrianroll]

Nice! Congratulations on your addition to the family! I've got a few....they keep my motorcycle projects from happening lol

 

[Hurco550]

Got a little more hackery done and mounted up the carb mounted up and made at last a temporary throttle cable for it. The bw200 clone carb came with a bent cable holder that didn't quite fit under the frame, so I swapped it out for a mikuni straight and short cable holder. The cable I had on hand also had the wrong style ball for the mikuni slide, so a little filling and hack style drill spinning with Emory paper and she is good to go. Once I figure up the wire harness and get spark, ill hopefully get this thing to fire. I feel like I'm at the point in this project that I have 90% of it done, and 90% left to go ha.

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[adventurco]

Looking good dude.

 

[Sonreir]

How's the electrical coming?

 

[Hurco550]

How's the electrical coming?

ha, I didn't get out to the garage till late. once I got to the point of wiring, I looked at your schematic and decided it was time to catch up on walking dead instead haha (it is a great schematic btw, im just a terrible electrician) hahaha

I need to get that capacitor from you at some point as well.

 

[Hurco550]

The more I I messed with it, the less I liked how the cheapo mini bike throttle felt. Both in function, and in that the cable came straight out the bottom of the throttle assembly. It seemed that it would be prone to getting snagged by tree branches in the woods and also, a failure of any kind out in the sticks could make for a long push back to base camp. I decided to try out a Yamaha blaster twist throttle conversion kit, since I know that the blaster used a mikuni as well. Feels like a quality piece of kit, BUT the exposed amount of cable at the carb/ slide end is to short, so I need to reduce the length of the sheath to expose more cable and put a new ferrule on it. Any advice on how to do so would be welcomed!

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[farmer92]

The more I I messed with it, the less I liked how the cheapo mini bike throttle felt. Both in function, and in that the cable came straight out the bottom of the throttle assembly. It seemed that it would be prone to getting snagged by tree branches in the woods and also, a failure of any kind out in the sticks could make for a long push back to base camp. I decided to try out a Yamaha blaster twist throttle conversion kit, since I know that the blaster used a mikuni as well. Feels like a quality piece of kit, BUT the exposed amount of cable at the carb/ slide end is to short, so I need to reduce the length of the sheath to expose more cable and put a new ferrule on it. Any advice on how to do so would be welcomed!

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Maybe try a copper pipe cutter to get the length right, then you just need to snip it lengthwise to get it off the cable.

 

[adventurco]

You should be able to drill out the dimple(s) on the metal end of the cable jacket to get it off the cable. Figure out how much exposed cable you need (I usually pull all the excess cable to one end and measure that way).

Cut around the cable jacket with a dremel cut off wheel and be very careful not to nick the cable itself. You can actually cut about 85% of the way through the metal coil "inner jacket" and then pop off the coils with a screwdriver. I usually pry them open and pull them off the cable, then pop your cable end back on and crimp it in place.

 

[Hurco550]

Thanks for the advice! Did exactly what you said, with one exception... I nicked the cable ugh.. ill keep an eye on it, but it'll likely eat at me and ill order a new one and try again. I also didn't care for the bind that the straight cable stay put in the cable, so I got an angled one, which should be much better.

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[adventurco]

Nice! As long as none of the strands broke you'll probably be ok. I try to cut about 80-90% of the way through and then break the rest of the metal jacket off so I don't hit the cable. Its a fine line.

 

[Hurco550]

I got a little time today to finish up the rear hub. I had a copy of the stock sprocket mounting bracket water jet cut and tig welded it to the extended bw200 hub. Then I chucked it up in the lathe to true it up and left a shoulder to keep the sprocket concentric. I replaced the original sprocket nuts and bolts with the pain in the butt bend over retainers with nylon locking flange nuts as well. Also, the cool looking ribbed bw200 front drum is the same dimensionally as the stock tw200 rear drum and literally bolts on. Once I get this the rest of the bike done, everything will get blown apart for paint, rear hub included.

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[JustinLonghorn]

Rad

 

[adventurco]

Nice work man. Looking good.

 

[Kanticoy]

This bike is stupid.






I love it though.

 

[Hurco550]

This bike is amazing, and you are amazing. Like a majestic bearded unicorn.




I love lamp.

ok, that was werid, but... thanks?.?.?

 

[Maritime]

Ha, nice work as always.

 

[Hurco550]

thanks gents!

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[Hurco550]

I decided that it really does NEED a fat front tire too. Once I source a set of bw200 triples and do a bit of machining, I'll be there. I picked up another bw200 gold front wheel with a new shoe to boot.

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[Popeye SXM]

Yer big tyres are great, love this build. This is my project, unfortunately after hurricane Irma I have very little spare time/ energy but when I get back to it I will start a build post. Thanks for documenting keeps me motivated