Not a good weekend for projects sadly. Today felt like a good time to tackle the the gearbox rebuild. [image: AP1GczON28f-2MsafJeD5d-5vpCddgE_F7wvwMw4mUgLb2qd4IhmX86P39IsZ82b_iWLEnwRqePbVAtntY2GH_ynSVKF-Pj2PWn_o11HKdPfEkiASpdPOuL8lcdFL_PBfKHjAhmRSBCEGtLjRGsR2fvnMhUA=w1341-h1083-s-no?authuser=0] Input shaft stripped ready to lay the gears onto the 1st gear conversion. [image: AP1GczOIOkdYg_118U84DE74bmnWa2tQKSoRjs7q2MOk0Q5fzTisZFT3fIl-MQKf_FuyjrvEYTMzvxMkhDYxFqDSyI7_TcHsUlsHK2RMHJcIgquU3WpNel8Fhugb5EeV3yOXCvv07VUZmQfQuSEcscoq6L-0=w1920-h901-s-no?authuser=0] [image: AP1GczOalIT8UP8GvsIu6oaCiebY2y1koDXD4F2rR4NZNUMeZhXVep5MHVKU92rHWzH24zPCUFbygSgL6E50bZfOwWG7Jm06MIV3hEjj8kd54GM1CLMGcMtcyoZvWKled2_dqcZEUpRv4ArxwKagYBJ8p_au=w813-h1083-s-no?authuser=0] All rebuild, new bearings, shims and circlips. [image: AP1GczO0QU9H7znj-nhFz4Cy18H8C6M08FS17ilL7ci8C9UVT24jFQ3yAVfARsbqKWkbHVAmy-v82EmVU1LFPcYTp0BPrMOdINfIRPttvzDjPvQfG7TyEwS_t2lEg_DFnWm_IVWg1en5V51sbSJk1a2LyzbB=w1920-h956-s-no?authuser=0] So far, so successful. Next tackling the output shaft. [image: AP1GczM5AdnAIDxi9C0cdm6iB-EQHGx1JXF0L7cjDoDM0JZsEhucD3y83x0wSP59PILgj3EGebFH0sLD02_NWCU3n4QVScZlhIonncHAx9tsflH_A6oXPv8Z_lS381ccF8N9qaGcmDhGjs_Kk5859zBhub4l=w669-h1083-s-no?authuser=0] Was going extremely well...until it came to dismantle third. [image: AP1GczO2Xjf9Y9WDogyaSfLEhfo_IP15jgPuKi_7M_zm2hUgacLm0cejxlpzFvdjoRv-F2aEkWNmIHKT0OSxbMPm9edFoMeWjJ1NMlepxIUHz8myGNfoxzAHBacbnRjoXDwnuAeFOCrppphFla0WHSMRzuRy=w556-h1083-s-no?authuser=0] This was not coming off and the prognosis wasn't good. Rough running third gear with swarf coming out of it. [image: AP1GczM62rE4VM-9MSlHtq3hT_6tAjAGc24wkdjOxyvjaJynqnqa5B8AwuSffkKGCxUp8L6uAOtp4AhpDkOswpwC8IH-SWsKlEzs7co4o5C1LtMxj1aklyd7e86f6J2AmzKg1jLQaMLcTIvSvdvjOrAyIzXO=w890-h1083-s-no?authuser=0] The layshaft's damaged beyond repair and so was third gear. Luckily the layshafts can be had brand new and I managed to find third gear. So sadly that's the cost of a used gearbox, but then that tells me for scrimping on the gearbox. The layshaft's coming from Japan so I'll have to park this rebuild for now.

Managed to source OEM indicators/mirrors (although not my taste personally). [image: JQleX2R.jpeg] A fair chunk of change was dropped on renewing brand new OEM NOS throttle, clutch, choke, Odometer cables. [image: m2jmkY1.jpeg] I also decided to paint the mild steel arrow pipe. Just make it look like a factory pipe and nothing fancy. I must have bought this pipe brand new 3 years ago and it's been in storage since and even then it's rusting.... It's no TYGA pipe for sure! Buzzing to get this bike complete though.

Finally! Actually found some time to go out on this thing! [image: L5TZajj.jpeg] The original gearing I bought for this was a no-go and I ended up chucking it in the bin. Instead, I found a Trail Tech crankset made for an E-bike, had to swap out the bottom bracket, but the result is something which gives me the ability to go up a few teeth on the front (currently rocking 24t), blitzes up moderate inclines, but lacks real top end. [image: faXVi2L.jpeg] I managed my usual route easier than the 26er, both up and down hill. It just felt like it handled the rocky sections better than the 26er, the lower gearing made it easier to climb some of the hills I had to get off and push, overall I'm very pleased about how this one has turned out, hopefully get a lot of use out of this over the coming years.

@Calum no worries mate. I would take a cad file if you wouldn’t mind sharing will likely send them off to a local machinist. I have a 3d printer as well so could try the cad file on there!

Hey, can someone tell me which springs fit in the wr 200 fork? I ride this bike with Supermoto rims. So im looking for stiffer springs.. Greetings from Germany

[image: 21mSygm.jpeg]

what are the four restrictions?

Small updates, rear sets refurbished and fitted. [image: KZc9g5J.jpg] Brand new OEM Genuine handle bars fitted. [image: PdA0H8Y.jpg] A quick five minutes with the buffer just to bring some shine to them. [image: wIU7bkI.jpg] Switch gear fitted and cables routed through. [image: DQukIxO.jpg]

You might have to earth out a wire on the CDI unit on your bike. There are some weird restrictions I don’t know about. Like my TZR had a black/green stripe wire earthed out on it…

@pedrobatista10 I'm sorry to hear that. BMW550d sounds nice though. At least you're still alive and breathing and it is good to hear from you. Maybe one day you can get an adapted shifter two stroke kart and enjoy that

@Calum What an excellent use of space, and a first rate job!! Steel section on the bench and a pillar drill somewhere will finish it off nicely.

@voiska [image: AJc5JmRtJu9qtrmvnWQq54CkFMXq6Kmj-ZmYI1VJwb63YCjSMyM1v2wa16vPQ8FND5TqnK82oUmPQz8=w3440-h1354] You can embed the picture into the post. [image: AJc5JmT9o2OHzCKpsLxBm0ddiXMrKjR4dZHIr6JqSZoCZYp9-ykifkG8X_gjAhVdGr6BjDlBMhYCyqI=w3224-h697] [image: AJc5JmRS4skawy37uQcPLPfbJ7sa7ABV_IFJrs9aEffJGj5Iyux76Skg-sZrL975pbERv4k_UYIiQ9M=w3224-h697] Looks like you've got a project on your hands!

@rraleks Who says it’s running lean? Overheating is caused by different things, lean is one possibility only. Check your radiator coolant level please mate... No way the crank has a 5.5mm longer throw! It’d of locked solid against the head... Please check your radiator coolant level!... I ran my bike well lean for 1000’s of miles without damaging the piston. It was only when my head gasket blew and emptied my radiator that it ran it hot enough to eat the piston, in the same way as yours...

@declan worth a try With the ybr sprocket hopefully works for you buddy

@spookdog yes metal type it seems fine with the rubber gasket but if I can't sort the squishing issue then I'll just go back to paper gaskets

Agreed! Shame because we are all desperate for bits now

@donaldmendez Thanks, it didn't take anyway near as long as I thought to get it up and running. I've just been doing some final touches. I'm going to ride this one on nice days Here's how she stands now. [image: W6qweVZ.jpg] [image: niTIsba.jpg] [image: CAmqx8Y.jpg] [image: TNcQAfZ.jpg] [image: g7Dj977.jpg] [image: or5MSQX.jpg] [image: cdw4lUS.jpg] [image: KmDDu3o.jpg]

@g646tvrs3 Different size overall I believe.

@Calum when he took a drink of the cola i thought it was real lol