TW200 Forum banner

1 - 20 of 31 Posts

·
Registered
Joined
·
31 Posts
Discussion Starter #2
I got this yamaha TW200 off my uncle for pretty cheap.







after a bit of net searching, i found they are a popular bike to customise over seas, and theres even a shop here in sydney that builds them, and sells them for pretty big money...



heres some of the ones i found on the net, that inspired me to start on it.











 

·
Registered
Joined
·
31 Posts
Discussion Starter #3
They look pretty tuff, and i decided to do the same thing to my bike, useing my own ideas and colour schemes..



After i showed Dave at restoremaz the pics of the modified ones, he was very excited about the whole thing,and offered to help.. and sugested we start right away.



so it began..project chunkey monkey!! The original print in the yamaha tw200 brochure says its a "chunkey monkey"...so the name has stuck.



Ok, here it is just minutes before the strip down....and Dave and i all keen to get started..















Striping the bike down...it dosnt take to long, but we took heeps of photos of every single part, and where it goes.....its important to do this, its a great help apon reassembly if you forget where something goes.









Couple of hours later....not much left.



 

·
Registered
Joined
·
31 Posts
Discussion Starter #4
next task was to extend the swing arm. Most of the moded bikes have had this done, it makes them look better, and gives the bike a longer wheel base.

we decided about 5 inches was enough...and went down to see Ross at mr enforcer engineering.



he sugested choping it, then inserting steel tube of the same shape inside the swing arm for strength, then welding caps over it to bring it back up to the normal thickness.



Cut and test fitting here...















trial fitted to the bike here, to see how it looks....



Already looking tuff!! :thrust:



 

·
Registered
Joined
·
31 Posts
Discussion Starter #5
After we were happy with how it was all looking, we finished striping it down, and sent the frame away to be sandblasted.



when it came back, we ground off any brackets and mounting points we didnt need.

we worked out which ones were to go before stripping the bike down, and marked each one with a small hacksaw blade cut.



grinding brackets off...







Next step was to etch primer the frame and get it ready for paint....

















Ok frames painted here.......decided to go with a gold basecoat.....im very happy with the colour...













Next we started on the motor.



We had got it running before we striped the bike. it had been sitting round for a while, and the carby was all jamed up with crystalized fuel and junk...we got it to run pretty good, but the only problem we found was the clutch was rubbsih. it was slipping pretty bad..so i ordered new clutch plates from yamaha.

we also detailed the motor as best we could.....









Striping motor down..







Painted up ......we kept the cooling fins in the alloy look....





 

·
Registered
Joined
·
31 Posts
Discussion Starter #6
New clutch plates..















Puting clutch back together and fitting new drive sproket...















We driped red paint into the "yamaha' lettering on the side of the engine....it took a bit of time, but it came out good.....









motor looking fresh..ready to go back onto the frame.



 

·
Registered
Joined
·
31 Posts
Discussion Starter #7
Ok, motor bolted back onto the frame here....with starter motor and coil .











The side stand, engine bracket and doubeling pegs needed to be sandblasted and repainted.













 

·
Registered
Joined
·
31 Posts
Discussion Starter #8
Next step was the battery holder/standard air box.

i didnt want that big and bulky box and air filter unit to spoil the bike, so i trimed it all down, and just left enough of it to suport the battery.

we replaced the standard air filter with a small one, and hid all the wireing up under the seat.



This is how it looked before.







triming it down, and fileing down all the edges...







Nice and small now, and all wireing tucked away under the seat.







 

·
Registered
Joined
·
31 Posts
Discussion Starter #9
Next we sand blasted all the steering and triple clamp parts...painted them up, and fitted new steering head bearings.

We also got a bike mechanic to rebuild the front forks, and fit new fork seals....the front gaurd is an off the shelf item for these bikes from a place in the city.



















New steering head bearings..











Front gaurd and forks fitted here.



 

·
Registered
Joined
·
31 Posts
Discussion Starter #10
next we got the swing arm sandblasted, smoothed out the welds, did some bog work, and painted it up, and fitted it back to the bike...



















 

·
Registered
Joined
·
31 Posts
Discussion Starter #11
Starting to look like a bike again now.......new handle bars painted and fitted here to...











Fuel tank time........

paint striping it down, repairing the dents and geting it ready for paint.











Back to bear metal....







old fairing tabs removed, we will not be refitting any of the side panels.....







Nicky work done here, ready for primer....











primered...







Here it is painted.......i chose satin white



 

·
Registered
Joined
·
31 Posts
Discussion Starter #12
geting there now.



some new parts, a new rear LED tail light...some smaller carbon fiber look blinkers, new handle grips and all of the axles and brake parts and chain adjusters freshly silver zinc coated.



















Time to get the bike rolling now.....



Rear tyre had a slight hit, so we heated it up, and panel beated it out till it was round again.....

painted up the wheels black, to give it that motard look, and fitted nice thick road tyres....they cost a pretty peny to :shock:











Bike rolling here.......tank fitted, along with handle grips,. brake and clutch leavers.







 

·
Registered
Joined
·
31 Posts
Discussion Starter #13
Exhaust was pretty much the last thing.

i bought some bends, and a muffler off one of those pit bikes...

we used the front flange part off the original exhaust, mounted the muffler underneath the bike, then joined it all up.







The mounting bracket on the muffler was in the wrong spot for the way we wanted to mount it, so we got Ross from enforcer to tig weld it into the spot we wanted...







original pipe and flange cut off...











Tacked all into place before welding....







Back off the bike, and Dave welding it all up....



 

·
Registered
Joined
·
31 Posts
Discussion Starter #14
well thats pretty much it. i just have to heat wrap the exhaust, and im still waiting for the new twin head light to turn up....

ive just put the original one on for now, but ill post pics of the new one as soon as its fitted.



here she is all finished and registered.

just have to get the carbie jeted and tuned, and ill be cruising round on it =D>



Ill also be retrimming the seat in white when the trimer reopens for the year...

















 

·
Registered
Joined
·
31 Posts
Discussion Starter #15
also 2 other vids on youtube!



http://au.youtube.com/watch?v=4s0Gof6Q5nQ



http://www.youtube.com/watch?v=3gsdnMOfKts



enjoy..





the bike has changes slightly, mostly tail lights as they keep breaking on me!



Future plans for the bike are....



Taller & narrower front wheel

Lower rear end by shorter shock or possibly a solid rear?

I have a small turbo charger i would love to see on the bike... not to add power as such, but just to try to get it to work and to hear the whistle!
 

·
Registered
Joined
·
555 Posts
the bike has changes slightly, mostly tail lights as they keep breaking on me!



Future plans for the bike are....



Taller & narrower front wheel

Lower rear end by shorter shock or possibly a solid rear?

I have a small turbo charger i would love to see on the bike... not to add power as such, but just to try to get it to work and to hear the whistle!
Fantastico!

Nicely documented progress pictures.

Thanks for showing us your work.

Looking forward to the updates too.

I am searching for dual round headlights for my TW.

I will probably go with the Honda Ruckus clones on eBay since I like the "rack" for the offroad look.
 

·
Registered
Joined
·
31 Posts
Discussion Starter #17
Thanks you!



Would you know what type of taller front wheel would fit my bike?



Also, I have a set of 3.5 inch dual round headlights for my Nike that I've never got around to fitting... Might throw them in for a change of look!
 

·
Registered
Joined
·
77 Posts
Good vid mate I've seen it on youtube before when I was trying to gain some custom inspiration. Good to see another Aussie on this forum let alone a Sydney sider. Good luck on your last touch ups.

Slinky
 

·
Registered
Joined
·
184 Posts
I really like your bike. Very nice work.



I have seen your project on another site and it has helped me customize my own bike.



I used your idea of shaving the cooling fins to bare metal and took it a step further and did my clutch side cover and oil filter cover as well. I also used your battery box idea, though your pictures made it look a lot easier than it was! It took a good bit of cutting and filing to get everything smooth.



Yours looks really nice. Did you use plastic paint on it? I buffed mine with a wire wheel to make it flat black.





I tried the DIY underhung exhaust, but mine didn't turn out as well as I wanted so I recently changed to an FMF universal muffler. Now I'd like to find or make an offset pipe to go from the muffler to the OEM head so I can tuck the muffler in tighter to the bike.



Thanks for all the documentation and pics of your project!







 
1 - 20 of 31 Posts
Top