[SURVEYWATERS]

1989 TW200 with 5434miles was about to be sacrificed to the Scrap God's when I heroically rescued him from an untimely demise, and for a mere $100. Everything is there except for the left mirror, tool kit and AIR FILTER!!. He's been sitting indoors all his life and is in remarkable condition. I plan to put a new topend on it and other obvious items such as brakes, bearings, cables, etc. The bike was running a few years ago but smoking heavily. Any suggestions, tips, or thoughts would be most appreciated. Also, I'm thinking about a different color scheme. I don't really want to change the tank, but the frame and plastics are all up for discussion.



At 13:05 the dub was smurfin' filthy:

AT 14:40 things were Smurf'd Up:

 

[TW-Brian]

Congratulations on the great find!



Good work on the fast teardown (I hope you took good notes so you will be able to put it all back together).

 

[SURVEYWATERS]

Notes? .....

Not my first, I've got "twenty seven eight-by-ten

colour glossy pictures with circles and arrows and a paragraph on the back

of each one"



In all serious though, I know most of what I'm doing, but the few tricky spots I snap a photo of and all bolt clusters go into labeled ziplocks. The tough parts not done yet. Getting the wiring harness routed properly during reassembly is where I've seen trouble. These bikes are simple though. Tearing down newer bikes like rockets and cruisers is really where you need ol' Obie.

 

[phelonius]

Rings, valve lap, total cleanout of carb and petcock and tank should see the engine in fine shape. Pump all the cable sleeves with oil, check condition of chain and sprockets, and tires, new battery and you will have a new 89 model prime ride.

 

[TW-Brian]

Not my first, I've got "twenty seven eight-by-ten

colour glossy pictures with circles and arrows and a paragraph on the back

of each one"

That'll work!

 

[2mchprssr]

Wow total teardown in an hour and a half. Impressive

 

[SURVEYWATERS]

Phelonius, your right on man, good check list.



The chain and sprockets were new when parked so I removed the surface rust and am soaking the chain in kerosene now. Rear tire is great but front needs replaced. Just finished inspecting and lubing cables. Does the boy need the battery to operate properly or will it run with out? Finally, I can't bring myself to tear it down, put $35 in gaskets on there and $25 in gaskets when I could go ahead and star anew with a fresh bore. It's worth the money imho.





Okay, the piston is standard(no rebore) so I'm looking at a 1st over. I found an interesting right up here that states the Wiseco piston for the yfm200 is a direct replacement and increases the compression to 10.25:1. Can anyone here verify this before I order and test it out?

Also, does the bw200 gasket set fit?

 

[ezman671]

Will run fine with no battery. Be cautious of old tires no matter how good they look.

 

[SURVEYWATERS]

Bummer, intake manifold is split abit, that's a $55 part.... Anyone ever seen a cheaper replacement? Looks like the Kazuma 250 manifold may work

 

[FortPayne]

Yeah it'll run great no battery, but bring a flashlight cause it will be brighter than your headlight.

 

[lizrdbrth]

The wire loom routing is in the service manual.



The only real touchy part is the CDI and alternator wires from the left engine side cover. Make sure they're routed within the side cover properly so you don't pinch them.



You may want to re-wrap the forward part of the harness where it passes over the frame near the rear gas tank mount.



Do the dielectric gease thing wire-by-wire on all the bullet connectors, etc.

 

[old mad max]

Wow.. Looking forward to the final package.... I can't even change one tire in a hour. (o; OMM.

 

[SURVEYWATERS]

I need some tips..



Does anyone have a suggestion for replacing the chain slide on the swingarm? Mine shattered and I'd like to replace it with something softer and cheaper. Also, the fork boots are hard and ugly, any thoughts there?



Update:

I plan to paint the frame yellow, the plastics will be going white and the engine will get a fresh coat, maybe coal grey. The tank and seat are in good shape and will stay blue. I'd like to find a local powder coater to finish all the brackets and misc. pieces.



Lizrdbrth, spot on with the harness, definite wear around the column. I have also apparently been screwed by a mouse... I'll be rebuilding a fair bit of the harness.





some updated pics

 

[PalmStateCrawler]

I think that color scheme will look really good, especially sitting next to the XR



OMM, don't start talking about changing tires...

This is who always helps me with my tires. And he LOVES doing it

lol. Thats some serious sarcasm!

 

[SURVEYWATERS]

Where in sky's name do I find the side cover grommets on the micro phiche!?! The ones that are mounted in the rear tank holes. I also can't find the frame grommets for the rear fender?



I'm not being lazy here, I feel like I've looked in avery relevant slide multiple times.

 

[lizrdbrth]

If you can't find them online try walking into the dealer. Yamaha uses that grommet on a lot of bikes in a lot of different capacities other than to hold sidecovers on. They may have a binful. Or at least a couple.

 

[SURVEYWATERS]

EDIT







found the grommet, it is labeled improperly for the '89, I found it in a later phiche





It's number 7

 

[SURVEYWATERS]

UPDATE





The o/s piston and cylinder went to the machine shop.

I have sand blasted and primed all the brackets/braces/Swingarm

Today I am blasting/priming/painting the frame and will be ready to start reasssembly

 

[lizrdbrth]

You get stuff done, doncha?



Ever seen a "Bumblebee" Beemer? That yeller frame would look pretty cool against black.

 

[SURVEYWATERS]

The old R100 and R80 BMW are very cool looking. Unfortunately, the wife is "helping me" pic the color scheme: white plastics, original blue tank paint w/ yellow to white decal, blue seat, blue bars, yellow grips, frame, and fork boots. I think it will look pretty good, just not as 'manly' as the Bumblebee.