DT200WR restoration project pic heavy
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@finnerz89 no because I'm only using the new clocks shell. All wires and bulbs I swapped over
wrote on 22 Dec 2018, 16:09 last edited by@Louis-James hmmmm
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wrote on 11 Jan 2019, 15:37 last edited by
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wrote on 11 Jan 2019, 15:59 last edited by
Looking good
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wrote on 11 Jan 2019, 16:06 last edited by
@finnerz89 thanks
I'll get some more videos outside on a nice day -
wrote on 11 Jan 2019, 16:11 last edited by
Yeah that looks mega!
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wrote on 14 Jan 2019, 19:21 last edited by
@Calum cheers mate.
Just finishing the final parts.
Going to inspect the oil pump drive gear to ensure its all ok as the guy before disconnected it.
The pump leaks from the oil seal. I've stripped, cleaned and ordered a new seal.
Always the last little things like the brake lights sensitivity etc to finish
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wrote on 16 Jan 2019, 18:18 last edited by
Need a bit of advice.
I'm not used to this clutch set up.I only removed the clutch cover to fit a new oil pump gear.
But when I put it back on the Kickstarter wouldn't crank.
After playing around I got that back into action.However there is no tension in the clutch lever.
I'm not sure it the clutch arm needs a full 360deg rotation.
I'm not very familiar with this setup.
The clutch operated fine before and was a new one when I bought the bike.Part 11 in this diagram just wobbles around.. but I'm not sure if it's correct.
https://www.fowlersparts.co.uk/parts/4098902/wr200r-4bf1-1992-999-a/clutch
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Need a bit of advice.
I'm not used to this clutch set up.I only removed the clutch cover to fit a new oil pump gear.
But when I put it back on the Kickstarter wouldn't crank.
After playing around I got that back into action.However there is no tension in the clutch lever.
I'm not sure it the clutch arm needs a full 360deg rotation.
I'm not very familiar with this setup.
The clutch operated fine before and was a new one when I bought the bike.Part 11 in this diagram just wobbles around.. but I'm not sure if it's correct.
https://www.fowlersparts.co.uk/parts/4098902/wr200r-4bf1-1992-999-a/clutch
wrote on 16 Jan 2019, 20:26 last edited by@Louis-James Did you not take any pics before you dismantled it???
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wrote on 16 Jan 2019, 20:51 last edited by
@NINJA I didn't dismantle anything.
All I did was removed the casing and replaced the oil pump gear.
I didn't touch the clutch.
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@NINJA I didn't dismantle anything.
All I did was removed the casing and replaced the oil pump gear.
I didn't touch the clutch.
wrote on 16 Jan 2019, 20:59 last edited by NINJA@Louis-James Well that's weird, maybe you have just discovered a fault before it ruined all your hard work???
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@Louis-James Well that's weird, maybe you have just discovered a fault before it ruined all your hard work???
wrote on 16 Jan 2019, 21:06 last edited by@NINJA I think I need to remove the clutch arm and rotate it. See what I find tomorrow haha
Wish I did it when the engine was out.
The water pipe it the biggest pain to fit. -
wrote on 16 Jan 2019, 21:18 last edited by
I had a similar issue on an old bike, the clutch arm operates like a rack and pinion, the arm being the pinion part. I had to engage it further down the rack to get the full range of movement. It's spring loaded, I hope that makes sense lol.
Current bikes:
DT125X '07
Street Triple R '11
Aprilia ETV1000 '02Previous:
DR650RSE '96
FJ1200 '92 -
I had a similar issue on an old bike, the clutch arm operates like a rack and pinion, the arm being the pinion part. I had to engage it further down the rack to get the full range of movement. It's spring loaded, I hope that makes sense lol.
wrote on 16 Jan 2019, 21:26 last edited by@finnerz89 it has a stability spring on the arm.
But it should be resisted by the 5 clutch springs.
Thanks yes it is a rack and pinion type -
@finnerz89 it has a stability spring on the arm.
But it should be resisted by the 5 clutch springs.
Thanks yes it is a rack and pinion typewrote on 16 Jan 2019, 22:14 last edited by NINJA@Louis-James These any good to ya???
http://mybikemanuals.com/yamaha/yamaha-wr-owners-manuals/
https://www.ebay.co.uk/itm/WORKSHOP-MANUAL-YAMAHA-WR200R-/332115601413
SEDUCED BY THE DARK SIDE!!!
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@Louis-James These any good to ya???
http://mybikemanuals.com/yamaha/yamaha-wr-owners-manuals/
https://www.ebay.co.uk/itm/WORKSHOP-MANUAL-YAMAHA-WR200R-/332115601413
wrote on 16 Jan 2019, 22:27 last edited by@NINJA thanks for that the link has the manual. Hopefully sort it tomorrow
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@NINJA thanks for that the link has the manual. Hopefully sort it tomorrow
wrote on 16 Jan 2019, 23:24 last edited by NINJA@Louis-James You're welcome - I'm not sure if they are for your model, as there's quite a few to download online. Just do a search for your model/year and you'll probably find the correct one???
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Is the clutch hub and basket lined up correctly seem to remember you can fit the dt one 4 different ways but will only work in one position
wrote on 17 Jan 2019, 11:19 last edited by@DTR-NSR thanks guys it's all sorted now.
Good thing I checked because the water pump didn't have a gasket in there
This is what happens when other people rebuild -
@DTR-NSR thanks guys it's all sorted now.
Good thing I checked because the water pump didn't have a gasket in there
This is what happens when other people rebuild -
wrote on 17 Jan 2019, 20:33 last edited by
@NINJA yes, this engine had a fair few leaks I sorted today
Oil pump
Gear lever seal
Water pump.
Also putting the water pump pipe back in caused many problems, took so many attempts to get it to seal.
But now have a fully functioning to 2stroke pump
.. as it was from the factory.
