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******EDIT******



I decided to add an index to the beginning of this thread because it is starting to get long....



Page 1: History of my TW purchase, Fly Aero Handlebars, Powermadd Handlebar Risers, Cycra Handguards, ProGrip Grips, High Mount Front Fender, LED Tail light, Wide Footpegs, Tool Tube.



Page 2: More Tool Tube, Beginning of Carburetor Testing, Bridgestone Tires, Tubes, Wheel Bearings, Brake Shoes.



Page 3: Powder Coating the Rims, Spokes, and Hubs.



Page 4: Tearing down frame for Powder Coating, Front Suspension Testing, New Heavy Fork Springs, Race Tech Cartridge Emulators, Beginning of reassembly.



Page 5: More Reassembly, Frame Crack Repair, New Black Plastics, New Forkboots, O2 Sensor Install.



Page 6: Seat Concepts Seat Foam and Cover, Yellow graphics installed, Building of custom rear rack.



Page 7: Riding in the snow, Continuing Carburetor Testing.



Page 8: Got a little sidetracked...., Continuing Carburetor Testing.



Page 9: Continuing Carburetor Testing, Clutch Basket woes..



Page 10: Clutch Basket Fix.



Page 11: Dyno Testing and Continuing Carburetor Testing.



*****END OF EDIT*****



Hello fellow Tdub enthusiasts!



I figured I'd start a build thread for my project.



I came about owning a TW200 in an unusual way.. I have riden dirt bikes since I was a child, within the past couple years I got excited about dual sport riding. I am a big guy, 6'5" and 260lbs. I own a very nice Husaberg 570cc dual sport bike and I love it! I built a trailer to pull behind my Husaberg so I could carry gear without adding racks to my bike. I then started building these trailers to sell. Long story short, a potential customer really wanted a trailer for his TW200 but he lived clear across the country. I ended up buying a TW just to build a trailer hitch for it for my dual sport trailers.



It turns out that I absolutely love this little bike! I'm sure I look like a circus bear on a minature tricycle, but I don't care, I can't help but grin every time I ride it. It is the little bike that can! I'm keeping the Tdub and turing it into a custom machine to fit me!



Here's a picture on the day I bought it:







Of course my first mod was to add a trailer:







Here are some hitch shots:







 

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The next mod was to help me be more comfortable on the little bike. Some taller bars and risers. I went with Fly Aero Bars and a Powermadd 2" Riser.







I was able to keep my stock cables even with the raised bars.



I also added Cycra Handguards to keep brush from hitting my hands while I blaze through the trails:







 

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Next, I made a bracket to put a supermoto fender up front:











I work at ProCycle, we specialize in the Big DR650. I fell in love with the TW and asked my boss to let me start building a page to support the TW200. He said "Do it!" so I've started building a page to help other owners find parts to customize their Tdub.



see the page here: ProCycle
 

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Today my son and I took the TW out for a ride! The little bike pulled us and a trailer up and over some local hills without missing a beat. It's so impressive that this little bike can carry us down the highway at 55mph and then climb up hills like a billy goat!















I broke the rear tail light today, so the next mod will be a nice and tidey LED rear tail light!



Get out there, Stay out there!
 

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Nice. How does one go about purchasing a trailer, I might ask?
 

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Very nice. Thanks for showing us that. Also, thanks for the work on the ProCycle site. I like the weld on foot peg extensions (among other things).



It's does me good to read about your enthusiasm for the bike. It makes me remember why it is good to get out there.
 

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Looks like a great time with your son! thanks for the pictures, I have been thinking about the high fender kit from you guys and those pictures sealed the deal...on my to do list for sure!
 

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Very nice. Thanks for showing us that. Also, thanks for the work on the ProCycle site. I like the weld on foot peg extensions (among other things).



It's does me good to read about your enthusiasm for the bike. It makes me remember why it is good to get out there.


In the near future I'm going to make new footpeg brackets that will allow you to mount newer Yamaha style footpegs to the TW. That will open up the options for footpegs big time! I like the ProMoto Billet footpegs myself, but there are tons options out there, even pivot pegs! Basically, any peg that fits the YZ/WR 250/450
 

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Kwizard said:
Great site. How about adding a carb kit for rejetting and rebuilding.


I will do that soon for the 2000 and older bikes. It might be a while on the newer bikes, as I don't own one of those.... yet....




I'm keeping my engine, jetting, airbox, and exhaust stock for now.. We have a dyno here, so I'm going to create a baseline with my stock bike and run each mod on the dyno to get some good data.
 

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with your red laces, blue jacket and the yellow on your helmet... you look camouflaged on the colorful '94! i like your fender bracket, nicely done.
 

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Whose hand grips are you using? They look fatter than normal.
 

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with your red laces, blue jacket and the yellow on your helmet... you look camouflaged on the colorful '94! i like your fender bracket, nicely done.


Ha Ha, I didn't even notice how well my son's outfit matched the TW! I won't tell him he matched so well, he thinks the 1994 color scheme is pretty ugly!



Whose hand grips are you using? They look fatter than normal.


They are called Rally Grips, made by ProGrip. I like them, they are very comfortable. They are a bit larger in diameter than usual, takes a little getting used to, but they really do cut down on vibration...
 

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Here's what I did to the tail light over the weekend...







So, I made a bracket to hold a LED tail light and the license plate:







It keeps everything up tighter than stock!







The LED tail light is very bright!!







The underside of the tail light has a couple white LED's that light up the license plate to keep it all legal.



I like it!
 

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I've also started proto-typing the footpeg mounts. I've got a couple questions to ask of other TW200 owners. I noticed on my 1994 model the right side footpeg is further forward than my left footpeg?? When you look down from above the bike, you can see the right footpeg is closer to the front of the bike. Is this to leave clearance for the kickstart lever to go further forward when you kick start the bike? Do the 2001 and newer Tdubs have the right footpeg further forward as well, even tho they have no kickstart lever? Perhaps I'm wrong, is there another reason for them to be different left to right?



I'm thinking of moving mine back a little and sacrificing some of the kickstart swing. What is everyone elses thought on this?



Here's what I've come up with so far:











These are some import pegs built for the YZ/WR 250/450
 

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Nice work on the tail light bracket and peg adapters, if you need a newer bike to beta test any fitment of your parts let me know I have a 2006. The pegs on my bike are a little cockeyed as well so may be a holdover from the kick bikes. Hopefully you will have these for sale soon and if so put me down on the list for a set.





I've also started proto-typing the footpeg mounts. I've got a couple questions to ask of other TW200 owners. I noticed on my 1994 model the right side footpeg is further forward than my left footpeg?? When you look down from above the bike, you can see the right footpeg is closer to the front of the bike. Is this to leave clearance for the kickstart lever to go further forward when you kick start the bike? Do the 2001 and newer Tdubs have the right footpeg further forward as well, even tho they have no kickstart lever? Perhaps I'm wrong, is there another reason for them to be different left to right?



I'm thinking of moving mine back a little and sacrificing some of the kickstart swing. What is everyone elses thought on this?
 

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Nice job on the pegs. Really looks good. (I just ordered the weld on ones two days ago...).
 
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