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THIS MOD INVOLVES THE STEERING CONTROL OF YOUR VEHICLE, AND BECAUSE OF THAT I NEED TO DO A DISCLAIMER.







DISCLAIMER





THE FOLLOWING ARTICLE IS WITH INFORMATIVE PURPOSES ONLY.



THE AUTHOR WILL NOT ACCEPT ANY RESPONSIBILITY OR LIABILITY FROM ANY PERSON OR ENTITY, REGARDING PROPERTY DAMAGES, VEHICLE ACCIDENTS, PERSONAL INJURIES OR DEATH AS RESULT OF ATTEMPTING TO OPERATE A VEHICLE MODIFIED UNDER THE NEXT DESCRIPTIONS.







THE MODIFICATION OR ALTERATION OF ANY PART OR YOUR VEHICLE CAN CAUSE MALFUNCTIONING, AND IN CONSEQUENCE, ACCIDENTS, PROPERTY DAMAGE, PERSONAL INJURY AND DEATH AND IS DONE UNDER YOUR OWN RISK.







INTRODUCTION:








I LEARN TO RIDE MANY YEARS AGO IN A TW200.



AFTER RIDING AND OWNING ALL KINDS OF BIKES, SMALL AND BIG ( HONDA, YAMAHA, KAWASAKI, BMW1100, ETC, ETC ETC).



I FOUND MYSELF CLOSING THE CIRCLE AND WANTING TO ENJOY AGAIN THE PACE AND SHAPE OF THE LITTLE TW200. THE DIFFERENT BIKE.







6 MONTHS AGO I START LOOKING WITH NO LUCK .



THEN , I PUT AN AD IN CRAIGSLIST WANTING A TW.



SOMEBODY OFFER TO ME A 1996 TW200 WITH 470 MILES , LOOKING LIKE NEW.



WAS GARAGED ALL TIME.



WAS A GIFT THAT I COULD NOT REJECT :$800 DLLS.



SO, HAVING SOME TIME AVAILABLE I STARTED TO DREAM ON PROJECTS FOR THIS BIKE.







I’M A RIDER VERY INTERESTED IN TWW MODS IN DIFFERENT BIKES (LIKE YAMAHA BIG WHEEL, HONDA FAT CAT AND OTHERS)







LIKE ALL OF YOU, MY INTEREST IN TW’2 AND SPECIALLY THIS MOD, DROVE ME TO RESEARCH SEVERAL MONTHS ABOUT THE SUBJECT SO SOLVE IT IN AN AFFORDABLE WAY.







BESIDES THE BEARD JAPANESE KIT ($1700 DLLS) NOBODY SELLS 4.5X14 RIMS OR WIDE TRIPLE TREES. MANY CALLS AND EMAILS TO MANUFACTURES AROUND THE WORLD PROOF ME THAT.







THE ONLY WAY TO GO WAS RECYCLING, USING PARTS FROM OTHER BIKES.











THIS BASIC AND CRUDE PROCEDURE THAT CAN BE UPGRADED AND ENRICHED CONSTANTLY WITH MANY IDEAS FROM EVERYBODY THAT COMPLETE THIS MOD, NO JUST WITH THEORIES.







I’M SHARING THE STEPS AND PROCESS THAT I FOLLOWED TO ACCOMPLISH THIS MOD AND ALSO THE SECOND OPTIONS.







I’M TRYING TO BE AS CLEAR AND SIMPLE AS I CAN.



SOME PARTS OF THE PROCESS INVOLVE ADVANCING AND ADJUSTING LITTLE BY LITTLE.







APOLOGIES IF SOMETHING IS MISSED OR NOT CLEAR, OR NOT WELL WRITTEN, WE WILL TRY TO CLARIFY, TIME WISE.

DUE TO LACK OF TIME I COULD NOT TO TAKE PICTURES OF THE PROCESS BY ITSELF, BUT I'M POSTING CLOSEUPS PICS OF THE WORK DONE.



.



I DID THE RESEARCH, GET THE MATERIALS AND THEN, FOUND A MECHANIC THAT WAS WILLING TO TRY THIS NEW JOB , AND AS A CONSEQUENCE, WE BECAME FRIENDS.

HE BASICALLY ASSEMBLED EVERYTHING AND CUTTING THE WHEEL HUB , SPROCKET , ADAPT THE BRAKE AND TUNE UP THE NEW FRONT END.







MAYBE YOU CAN DO BY YOURSELF, MAYBE YOU WILL NEED THE HELP OF A FRIEND OR A MECHANIC OR BOTH.





ANY YOUR IDEAS , DO IT SAFELY.







PROS AND CONS:







CONS:



-THE VEHICLE HAS LITTLE MORE TIRE DRAG, A LITTLE LESS SPEED, AND LITTLE LESS FRONT BRAKE POWER.

CAN BE FIXED.

THIS IS A WORK IN PROGRESS.

I'M WORKING IN IMPROVING THIS ASPECTS.

I WILL KEEP POSTING THE PROGRESS.







-THIS MOD IS FOR FRONT DRUM BRAKE STYLE (DISC BRAKE NO ATTEMPTED BUT IS FEASIBLE WITH ALMOST THE SAME STEPS)



-STOCK SPEEDOMETER WILL BE UNUSABLE.







PROS:



-LOTS OF STABILITY AND TRACTION



-ONE TIRE SIZE FITS BOTH



-EASY TO RIDE, EVEN MORE THAN STOCK



-ECONOMIC: $300 APPROX IN PARTS MORE OR LESS, DEPENDING WHERE YOU FIND THE PARTS, THE LABOR IS UP TO YOU AND YOUR MECHANIC.



-LOOKS AND FEELS GREAT



-LOTS OF FUN AND NEW FRIENDS.



























TW200 TWW MOD (TWO WIDE WHEELS MODIFICATION)









LIST OF PARTS :







WIDE TRIPLE TREE







TW200 REAR WHEEL ASSEMBLY:



(TIRE & TUBE, WHEEL, REAR AXLE)







REAR BRAKE ASSEMBLY:



(DRUM, HUB PLATE, SHOES, LEVER CAMSHAFT)























THE PROCESS INVOLVES WORK IN 4 AREAS, IN THIS ORDER:







1-TRIPLE TREE



2-FORKS AND AXLE



3-BRAKE



4-WHEEL








1-TRIPLE TREE:







OPTION A) TESTED





-USE OF A WIDE TRIPLE TREE FROM A YAMAHA BIG WHEEL BW200 OR BW350, IT WILL FIT IN THE TW200 FRAME DIRECTLY WITHOUT MODIFICATIONS.







CAN BE USE THE SAME BEARINGS AND NUTS. IT WILL ACCEPT TW200 FORKS.



(I FOLLOWED THIS PROCESS)







OPTION
NO TESTED






- USE OF A WIDE TRIPLE TREE FROM A YAMAHA THREE WHEELER (TRI-Z )



IF THE STEERING STEAM DOES NOT FIT, CAN BE REPLACED WITH THE STEERING STEAM FROM THE TW200 TRIPLE TREE.



THE PROCESS TO REPLACE IT CAN BE FOUND IN THIS WEB SITE:







http://www.flowbenchtech.com/porting/CRH/dd bike/OMR_ZX-636_Front_End_Conversion.pdf







OPTION C) NO TESTED





- USE OF A WIDE TRIPLE TREE FROM A HONDA, SUZUKI, KAWASAKI THREE WHEELER ,FOLLOW THE SAME PROCEDURE THAN OPTION B, JAPANESE BIKES SHARE A LOT OF COMMON PARTS AND SIZES.





- FIND ABOUT THREE WHEELERS HERE:







http://www.3wheeler.org/











2-FORKS :







OPTION A) TESTED



- USE A PAIR OF FORKS FROM A YAMAHA BIG WHEEL BW200 OR BW350, THEY WILL FIT IN THE WIDE TRIPLE TREE AND, THE IMPORTANT PART, WILL ACCEPT THE TW200 REAR AXLE



OR A YAMAHA BW200 OR YAMAHA BW350 FRONT AXLE, WITHOUT MODIFICATIONS.



(I FOLLOWED THIS PROCESS, YAMAHA BW200 FRONT FORKS ( THEY ARE A COUPLE INCHES LONGER THAN TW'S ADDING CLEARANCE ) AND AXLE)







OPTION
TESTED PARTIALLY






USE TW200 FRONT FORKS (THEY FIT PERFECTLY ON A BW200 TRIPLE TREE)



AND BORE THE HOLES AT THE SAME DIAMETER OF THE NEW AXLE.



(CAN BE DONE TO IN A MACHINE SHOP)







THE AXLES (FRONT AXLE FORM BW AND REAR AXLE FROM TW)



HAVE THE SAME DIAMETER.



THE LENGTH OF THE BW200/BW350 IS 13.25” , FITS PERFECTLY WITH THE TW200 FORKS BORED AND TRIPLE TREE.





THE LENGTH OF THE TW200 REAR AXLE IS 14.25”



MAKE THE PROPER ADJUSTMENTS WITH WASHERS AND SPACERS IF YOU USE THE THIS ONE.





3-BRAKE:







-USE OF A YAMAHA TW200 REAR BRAKE COMPLETE WITH ALL THE COMPONENTS



(DRUM, SHOES, HUB PLATE, LEVER CAMSHAFT)







OPTION A) TESTED



-IT WILL BE NECESSARY TO MODIFY THE CHANNEL THAT HOLD THE DRUM HUB PLATE IN POSITION WITH THE FORK, MAKING IT WIDER IN ORDER TO ACCEPT THE BW200/BW350 FORK.



(AGAIN, USE OF THE GRINDER)



-REPLACE THE REAR BRAKE LEVER CAMSHAFT FOR A FRONT BRAKE LEVER CAMSHAFT,



IT WILL MAKE EASIER INSTALLING AND ADJUSTING THE BRAKE CABLE.



-USE A COMPRESSION SPRING TO ALLOW THE LEVER CAMSHAFT RETURN EASILY TO OPEN POSITION.



(I FOLLOW THIS PROCEDURE)







OPTION B)NO TESTED






-IT WILL BE NECESSARY TO MODIFY THE BOTTOM LEFT FORK, MAKING THINNER THE PROTUBERANCE THAT HOLDS THE DRUM HUB PLATE IN PLACE, SO IT CAN ACCEPT THE WHOLE PIECE IN PLACE



(AGAIN, USE THE GRINDER).



REPLACE THE REAR BRAKE LEVER CAMSHAFT FOR A FRONT BRAKE LEVER CAMSHAFT,



IT WILL MAKE EASIER INSTALLING AND ADJUSTING THE BRAKE CABLE.



USE A COMPRESSION SPRING TO ALLOW THE LEVER CAMSHAFT RETURN EASILY TO OPEN POSITION.























4-WHEEL:







OPTION A) TESTED




- USE OF A YAMAHA TW200 REAR WHEEL WITH ALL THE BRAKE COMPONENTS



(DRUM, SHOES, HUB PLATE, LEVER CAMSHAFT ).





- WILL BE NECESSARY TO DISMOUNT THE TIRE AND REPOSITION IN THE CORRECT DIRECTION,



(THE ORIGINAL LEFT SIDE OF THE WHEEL, NOW WILL BE THE RIGHT SIDE)





- WILL BE NECESSARY TO CUT THE PLATE THAT HOLDS THE REAR SPROCKET



( USE A GRINDER)





-WILL BE NECESSARY TO TAKE OUT THE BEARINGS OF THAT SIDE (2) AND CUT THE HUB AND ALSO CUT THE INNER SPACER , AS MUCH AS NEEDED ( 1/4 " APROX ), AND THEN INSTALL JUST ONE BEARING IN THAT SIDE.





-YOU WILL FIND HOW MUCH YOU NEED TO CUT WHEN YOU CENTER THE WHEEL,



ASSEMBLING EVERYTHING:



THE WHEEL, THE DRUM BRAKE AND THE AXLE INTO THE WHOLE FORK SETUP.







-USE AND ADJUST SPACERS AND WASHERS AS NEEDED.











-ASSEMBLE THE WHOLE SET-UP USING GREASE, LOCKTITE AND TORQUE AS NECESSARY TO ACCOMPLISH A SAFE WORK.







EXTRAS:





.

1-IGNITION AND LIGHTS





OPTION A)TESTED








- WILL BE NECESSARY TO REPOSITION THE IGNITION SWITCH AND THE MAIN LIGHT AND BLINKERS SETUP.





- CAN BE ACCOMPLISHED THIS USING A PIECE OF ALUMINUM ANGLE OF



1 3/4" WIDE , CUT IT A THE PROPER SIZE AND DRILL THE HOLES TO FIT ON THE TRIPLE TREE.





-THEN ,FIND THE PLACE TO MAKE THE NEW SPACE AND HOLES FOR THE IGNITION SWITCH AND THE MAIN LIGHT AND BLINKERS SETUP.











2)SPEEDOMETER.



OPTION A) TESTED









-I WILL BE NECESSARY TO INSTALL A NEW DIGITAL SPEEDOMETER (SINCE THE STOCK SPEEDO WILL NOT WORK ANYMORE IN THIS MODIFICATION).





-USE TRAIL TECH 75-201 AND ADJUST IT TO YOUR NEW FRONT WHEEL DIAMETER.











3)FRONT FENDER.



OPTION A)TESTED







- WILL BE NECESSARY REPOSITION THE FRONT FENDER, EITHER USING THE HOLES IN THE BOTTOM OF YOUR TRIPLE TREE (THEY USE TO HOLD THE ORIGINAL WIDE FENDER) OR USING U-BOLTS ,OR MAKING YOUR OWN BRACKETS TO HOLD SECURE AND FIRMLY ,THE FRONT FENDER AGAINST THE TRIPLE TREE.







4)FINAL RECOMMENDATIONS.




TAKE A LOT OF PICTURES, UPLOAD YOUR PROJECT HERE IN THE FORUM AND, MUST OF ALL : ENJOY AND HAVE FUN !







5)PD: PLEASE , RIDE SAFE.








THANKS



FELIX



SAN DIEGO, CA



2/02/11TWW MOD PICTURES
 

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Thanks for posting this. Please keep us updated on the reliability of this mod.
 

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Hey Felix,



Thanks doing all the hard work and preparing a nice write-up! Looks pretty straightforward and relatively simple. I anticipate there will be a lot of guys looking for BW front ends now.



Well done!



Brian
 

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What an awesome write up and pictures to go with it, you did an excellent job. You have yourself a sweet looking machine. Thank you.
 

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Can I assume you converted those two fuel cans as panniers? Pretty neat and inexpensive idea.



Dan
 

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Discussion Starter #14
Can I assume you converted those two fuel cans as panniers? Pretty neat and inexpensive idea.



Dan
YES, THEY ARE PLASTIC JERRY CANS,YOU CAN CHECK THEM IN THE TOPIC



PVC RACK AND PLASTIC GAS CONTAINERS AS PANNIERS



I USE THE PVC RACK DAILY FOR 4 MONTHS WITH ZERO PROBLEMS.

NOW I SAVED SOME $ AND PUT HAPPY TRAILS FRONT & SIDE RACKS.

I KEEP USING THE PANNIERS. I WILL INSTALL THE PVC RACK ON THE FAT CAT.
 

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AWESOME!!!!



Okay, I now have a really bad headache from reading your CAPSLOCK writeup. Worth every throb.



Question: You mentioned the BW forks being "lower" than the TW forks, but your bike does not appear to be sitting low in the front in the pictures. Do you mean the axle is lower in relation to the triple tree?



Might I suggest the TW32 tread pattern would likely work better on the rear wheel and the TW34 would likely work better on the front. Function aside, those TW32s are old, and old tires often fail in spectacular fashion. A blowout on a front tire is much more dangerous than a blowout on a rear tire. Just for safety's sake, mount a new TW34 on the front and save the TW32 for the back. Genius like yours would surely be missed.
 

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Discussion Starter #16
AWESOME!!!!



Okay, I now have a really bad headache from reading your CAPSLOCK writeup. Worth every throb.



Question: You mentioned the BW forks being "lower" than the TW forks, but your bike does not appear to be sitting low in the front in the pictures. Do you mean the axle is lower in relation to the triple tree?



Might I suggest the TW32 tread pattern would likely work better on the rear wheel and the TW34 would likely work better on the front. Function aside, those TW32s are old, and old tires often fail in spectacular fashion. A blowout on a front tire is much more dangerous than a blowout on a rear tire. Just for safety's sake, mount a new TW34 on the front and save the TW32 for the back. Genius like yours would surely be missed.


THANKS.

THE BW200 FORKS ARE LONGER BY 2 ", NO LOWER.

I WILL USE TW32 REAR AND TW34 FRONT AS YOU SUGGEST. THANKS
 

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THANKS.

THE BW200 FORKS ARE LONGER BY 2 ", NO LOWER.

I WILL USE TW32 REAR AND TW34 FRONT AS YOU SUGGEST. THANKS
I went back and reread your part about the forks. Darn dyslexia makes it very hard for me to read ALL CAPS.




I'm planning dual stock front disc and calipers on custom spacer/adapters and a TW34 tire, a slightly extended swingarm, and an ATV rear tire on a 12-inch aluminum trailer wheel with the stock front disc and caliper for a brake. All it takes is money, and all mine is going to pay off medical bills right now.
 

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This looks great. I am on my second TW and always liked the fat tire on the front idea. Starting looking into more seriuos as of late and I used some info from this post to undertake the project. I am going in a little different area with the brake, as I did'nt want the rear brake(smaller)on the front. So if you look at the drum brake model tw's the brake drum is bolted to the hub with a 3 bolt ring. This is the same on front and rear. I purchased an extra set of rims(front and rear) and removed the front brake hub from the wheel hub(spoke holes are evident)and bolted it on the rear rim. The rear hub sprocket flange has to be removed(alot of cutting and grinding) and hub trimmed with one bearing removed just like mmannddalla did. Also, I'm using the stock tw forks in the BW 200 triple tree so I drilled out the forks axle holes and front wheel brake hub hole to use the larger rear axle. The front axle is 15mm diameter while rear is 17mm. So not much material is removed for that, and then the front brake hub slips into front fork leg retainer without modification there. Also had to cut rear axle spacers to get wheel centered in forks(have to use rear stuff to fit axle). I'm still in work as I have to mount my Shinko tires front and back. I also am going to paint both rims black.
 

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Forgot to mention that the bw 200 triple tree and bearings are a bolt in but the one I have needs a mod on the steering stop to keep the fork leg from hitting the tank on one side.
 
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