Engine Repair
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Thread: Engine Repair

  1. #1
    Senior Member thumper's Avatar
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    Oct 2010
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    Just wanted to share my latest repair work.

    Both the twins started leaking oil at both the base and the head gaskets.

    I ordered all the parts, and jumped in with both feet over the weekend.

    It was pretty easy. I removed the seat, tank, side covers, carb, exhaust pipe, etc.

    located TDC, pulled the head, then the cylinder.

    I had A&A racing hone the cylinder and since I already had approx 6K miles on her,

    I decided to replace the piston and rings as well.

    The cylinder had some light scratches in it that came out when honed.

    The timing chain guide (rearward one) had SEVERE wear on it. It was chipping

    off pieces of plastic and dropping them in the engine! I replaced this guide as well

    It cost about $50 bucks. I encourage you to check the wear when you reach about the

    same mileage, or you start seeing black stuff in your oil change!

    Everything else went smooth.

    The only thing that was tricky was holding the cylinder in one hand, guiding the chain with the other,

    making sure it didn't fall off the bottom sprocket, and squeezing the rings etc.

    I got it all together, checked everything, and attempted to start her!

    Thats when I thought I destroyed the motor!

    I forgot that I only filled the fuel tank up with less than 1/2 gallon of gas, and didn't

    have the lever on reserve! it started first kick, but then started coughing and went thunk and stopped.

    My heart was racing! I figured the fuel problem out and started it again. It ran this time, but only

    at Idle! Something was seriously wrong.

    This is what I found...

    When I lined up the timing chain sprocket with the mark I was sitting on the floor more towards the rear of the bike

    instead of directly in front of the mark. needless to say, I was off (1) tooth on the sprocket. The line was in the center

    of the link instead of in between two links (I was smart enough to take photos before I started).

    Long story short, I pulled the sprocket, rotated it one tooth, the stars aligned, the bike started first kick,

    and has never run better! I've got 300 hundred miles on it the first day going 45mph or slower! What a long day that was.

    Just wanted to share, as I'm pretty proud of myself.

    Now as soon as the wifes bike arrives, I'll do it all over again.

    Igofar

  2. #2
    Senior Member Gerry's Avatar
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    Jul 2010
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    IgoFar, good to see you back. Appreciate the info on the work you did on the upper end, hope I don't need to go there. Should I be unlucky, your info will help alot. At first, I was a bit confused. When a fella makes reference to the "twins" it seems, he is talking about his testicles. Thats ok of course, but figured it would be best posted in 'Other' rather than 'Technical'. Then again, problems with the 'Twins' can get pretty technical. Glad all is well. Thanks again for the info. ( ) Gerry



    Take care my Friend.........

  3. #3
    Senior Member abyssdncr's Avatar
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    Sep 2010
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    Wichita, KS
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    Quote Originally Posted by igofar View Post
    The timing chain guide (rearward one) had SEVERE wear on it. It was chipping

    off pieces of plastic and dropping them in the engine! I replaced this guide as well

    It cost about $50 bucks. I encourage you to check the wear when you reach about the

    same mileage, or you start seeing black stuff in your oil change!


    I have an '06 like Gerry and just did the base gasket at 5k miles. We both have the newer automatic cam chain tensioner and I was pleasantly surprised at how little wear the cam chain guides had. Might be worth watching the classifieds for a newer version for good measure.



    I empathize with you on the cam chain though, mine slipped off the crank sprocket after I'd gotten the head torqued and it took forever to hook it back up again!



    Another note, after hearing about another member who commented on his cam chain being half a tooth off, I snapped a quick cell pic of the cam sprocket location with the crank lined lined up and also observed my cam being about half a tooth off. The pic really saved me during reassembly...



    Glad to hear you're on the road again - satisfying, isn't it?
    2006 TW200, LED tail & turn signals, Clarke XT350 tank, hybrid YZ80 forks, CycleRacks rear rack, Ricochet bash plate, TTR225 header, eBay pegs, MSR high ATV bars, Tusk bar risers, Tusk handguards & deflectors, Tusk KX250 stainless brake line, XT225 speedo cable, 14/47 sprockets, Mule-pin seat latches, 130 main, 0.035" shimmed needle, TW34/M6006 meats.

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  5. #4
    Senior Member Rainman's Avatar
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    Good for you! I'm happy that it all worked out. The next bike will be a breeze.
    If you can't find it, grind it

    1990 TW200

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