Changes by year to the USA TW200
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Thread: Changes by year to the USA TW200

  1. #1
    Super Moderator Purple's Avatar
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    Changes by year to the USA TW200

    Trying to think of various changes by year to the USA TW200 – so feel free to chime in on this …..

    1987: One off electrical system, some of it AC, such as the head light. Reports of CDI failure. “Unsubstantiated” reports that this year was the fastest, but the ’87 did have a slightly tweaked CDI advance curve.

    1988: Revised electrical system, mostly DC.

    1987 to 1991 and 1992 to 2000 front brake shoes different sizes - choose replacements with care (see post #33 on this thread)

    1996: Front fork drain screws discontinued.

    2001: Changed to disc brake model. Rear foot peg off set changed. Charging system upgraded from 35W to 55W. CV carb introduced, with throttle cables coming in from the other side. Inlet manifold dimensions changed slightly to accommodate CV carb. Kick starter assembly no longer included (but can be added later). Trip meter added, Some electical connectors changed. Handlebar controls updated. Introduced automatic cam chain adjuster. Exhaust mounting changed (see post #17)

    2002: Smaller diameter fuel cap.

    2006: Multiple (increased) reports of leaking base cylinder gasket - see post #21 (Solution is to re-torque, or order later gasket which was stronger).

    2009: Base gasket problem resolved at factory.

    2017: Rear shock unit changed (no improvement).

    See post #26 regarding spoke diameters - " '99 has 3.5mm spokes, '15 has 4.0mm spokes"

    Throughout the years the CDI part number keeps changing, but how relevant this is has yet to be determined, though it’s likely to be a connector type issue rather than a performance issue. Details of CDI part numbers by year can be found here - https://tw200forum.com/forum/technic...nits-year.html

    Any corrections or additions welcomed – this is a joint “hive mind” effort. Once it settles down we can “sticky” it.

    Of particular interest, is the stator assembly, and the crankcase housing it – any info on that issue appreciated.

    I’ll edit this first post as we go along …..
    Last edited by Purple; 09-25-2018 at 10:35 AM.
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    Super Moderator littletommy's Avatar
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    Dyno results DID prove the mighty 87 WAS just a little faster...
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    Senior Member sibyrnes's Avatar
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    Actually the rear shock was changed in 2017. Does anyone know what the difference is other than the part number?
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    Ken
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    Good data. My 1993 had the leaky base gasket also.
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    Senior Member Nicoradv's Avatar
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    2001 9k miles base gasket leaking.

    2018 According to Happy Trails the muffler mounting has been changed to put it further in side the frame. Need to check tail light location mounts compared to older models. Seems like they way moved also.
    This according to HT when I went to mount HT tail and side racks to a 2001. Going by the way the bolt holes were off I can sorta believe it.
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    Super Moderator Purple's Avatar
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    Good info - keep it coming ......
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    Super Moderator Purple's Avatar
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    Quote Originally Posted by sibyrnes View Post
    Actually the rear shock was changed in 2017. Does anyone know what the difference is other than the part number?
    The adjuster was moved to the outside - https://tw200forum.com/forum/performa...prung-not.html

    On the original, you had to compress and remove the spring to get at it - now you have to compress and remove the spring (but getting at it is easier) ....
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    Senior Member vanillagorilla1's Avatar
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    2001+. trip meter added, electical connectors changes throughout the bike along with the other electrical changes. handlebar controls updated, throttle cables changes along with the carb and throttle tube. automatic cam chain adjuster.

    somewhere early on the rear tire changed. too bad cause I liked the old style one much better.
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    Super Moderator Purple's Avatar
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    Yeah - not sure when they changed the TW32 for the TW34

    First post updated ......
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    Senior Member plumbstraight's Avatar
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    The secret to the fast 87 is out. It was one tooth higher geared. a 49 as opposed to the 50. Not much, just a slight edge, who would have known.
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