The wr200 3xp / dt125r 3bn hybrid 200cc engine no.2

[Louis-DT-WR]

@finnerz89 thanks, I chose at random tbh as the samples are so hard to tell from in my experience but happy with the outcome

[Calum]

@Louis-James They've come up well.

I was always really sceptical about powdercoating the crank cases.

[declan]

@Calum howcome

[Louis-DT-WR]

Finally arrived

[NINJA]

@Louis-James Very cranky!!! :smiling_face_with_open_mouth_cold_sweat: :face_with_tears_of_joy:

[Minia]

Looking good! Then again everything you do looks outstanding to me.

[Louis-DT-WR]

@Minia thanks man. I like to do my best

[Louis-DT-WR]

New powervalver but not genuine from Greece.

[NINJA]

@Louis-James If it's not genuine then what are the Yammy packets for??? :confused_face:

[Louis-DT-WR]

@NINJA the powervalve is a reproduction. I have lots of brand new genuine parts that came from fowlers

[Louis-DT-WR]

What is this? I've not seen it before from memory clips inside the splined washer .

[Louis-DT-WR]

Cases bored out for the larger crankshaft

[NINJA]

@Louis-James Sweet looking job dude. :clapping_hands:

[Calum]

WOw, that looks superb!

[Louis-DT-WR]

@Calum @NINJA cheers lads. When you're rebuilding an engine that the previous owner "rebuilt" themselves you soon realise how many parts were missing, damaged or incorrect. Any help with the clutch washer ? Still need to do 1 more fowlers order. Pistons on its way

[2stroketerry]

@Louis-James Great little engine your building and like seeing quality work that you do. When i put a 57mm stroke crank in mine didn't fit the washer under the PRIMARY DRIVE GEAR NUT so the so the nut had the maximum amount of threads to screw onto.

The tabbed washer inside the splined washer is used to set the mainshaft endfloat on the clutch on some yamaha engines as they mix and match some gears inside the crankcase.
Was thinking of using this on my new engine build but now decided to see what i can build using the Athena 170 kit so just bought them.
https://www.ebay.co.uk/itm/YAMAHA-WR-200-3XP-4BF-NEW-SLEEVED-BIG-BORE-68mm-Cylinder-PISTON-3XP-11311-00-00/113185389112?hash=item1a5a5ffa38:g:3fwAAOSwEfBbZ3Je

@Louis-James where did you get the final drive shaft from as need one for my new build. thanks

[Louis-DT-WR]

@2stroketerry thanks man, I also ran a blaster 200 crankshaft on my original 200cc engine but wasn't happy with less gear meshing between the primary drive and clutch.

With regards to the tab washer.. I can't see it on any exploded diagrams. What years use it?

The final drive shaft I got brand new on eBay from Greece , £30 from memory, from Yamaha it's around £100

[Irongamer727]

Won't the 199cm3 text be an issue at the mot?

[2stroketerry]

@Irongamer727 I have an Athena 170cc kit with a 65mm piston in it that has 124cm3 cast on the side as well as Yamaha 5ML00 on it even though there is no such Yamaha cylinder number so no probelems with mot, police or insurance wise. The cylinder has a base spacer and has been skimmed to the correct compression ratio as well as the exhaust port and powervalve modified being 5mm wider, the transfer ports are raised by 1.5mm. Running the standard tm28 carb with power jet blocked and a 310 main jet it makes maximum power at 11,500 rpm and 37hp. No idea of top speed but running standard 16 57 gearing it goes straight off the clock in 5th gear but clock only goes to 80mph and will rev to maximum revs in 6th gear so it
probably does about 100mph. Was going to gear it up but wheelies mental and when gets to 10,000 rpm it just goes mental with power.

[Louis-DT-WR]

Many MOT testers don't care tbh, but you could file the numbers off or do your big bike test.

I think 2 strokes cc should be measured from above the exhaust port anyway