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mix and match?

1088 Views 7 Replies 5 Participants Last post by  jontow
hey guys, been a lurker for a while, reading lots, great site.

So i recently was picked up a couple TW200's site unseen for a good price thinking i could at least get one to go. first one is the beauty, 2006 with 3000 miles on it, mostly complete minus CDI; second one is the beast 1991, looks a little rough missing carb and CDI. I have no idea of the history of either bike.

I was able to find a CDI on ebay for the 06 so i started with that one. started cleaning it up, and when i changed the oil the filter was full of metallic flakes/sledge, not sure if these bike are prone to that or not, would have thought by 3000 mile the case would be cleaner, so i am assuming something is buggered on the inside. after cleaning out and refilling it i tried the starter and it would just click like a dead battery, but power was getting to the starter. pulled starter a part looked good, put back in and now it will turn weakly a couple times and then click again, and the battery was strong even tried boosting off my truck. bike has spark. finally it does not seem to be getting fuel when trying to start, and the carb is clean, can see light through all the jets. just stumped, so i moved on to the 91.

the starter on the 91 cranks nice and normal, and with the kick start i the motor feels right. but no carb or spark stops me there.

So long story short, can i use the 06 carb on the 91 bike, and any mickey mouse way to bridge the newer cdi to the old bike to test it? or am i better off swapping the 91 motor into the 06, probably have to swap the charging system?? maybe just swap the starter to the 06 and see what happens?

anyways sorry for the novel, just trying to wrap my head around these bikes as they look like a tonne of fun.

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Thanks for the replies guys, gonna be tied up til the weekend then i will get back into this. I have done the relay jump with a set of pliers and it is okay, didn't turn the starter but put power to the starter. (this was before i removed it and cleaned it up to get it to spin freely).

I am thinking i will put the 91 starter that i know is good into the 06 to rule that out.

Also the piston is not seized as i did try to jump start it and it turned over, just sounded off, so i stopped and want to dig into it.

Aside from that the left side cover on the 06 is cracked and weeping oil neat the top of it, so are the side covers different due to the difference charging internals? or can i swap the 06 charging bits into the 91 cover and engine?

sorry for the questions, i'm sure once it is all in front of me some of this stuff is apparent, just want to know if i should be ordering sourcing a left cover to avoid further delays.

thanks again!
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Sorry for the long Break here, finally got some time in the shop.

Originally when i said it sounded off, it was the engine, sounded like something wasn't right on the inside, maybe rings are gone, not sure.

But thanks to all your help i did go ahead and swap the motors out and changed over the stators, pretty straight forward. For anyone who hasn't read it somewhere, the rear axle of the tw can be used as a rotor puller as it is the same 16mm tapered bolt. Saved me a day of screwing around.

So got it all buttoned up and actually got it running. seems to only run with the choke fully on, and won't take any gas or it will die. So have to do some reading up on carb adjustments and go from there, but pretty excited to hear it rumble to life!!

thanks for the help guys.
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