DT200WR restoration project pic heavy
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@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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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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@Louis-James Did you not take any pics before you dismantled it???
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@Louis-James Well that's weird, maybe you have just discovered a fault before it ruined all your hard work???
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@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 -
@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
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@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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@Louis-James A bullet dodged there dude!!! :thumbs_up_light_skin_tone:
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@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.
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@Louis-James Nice one, I feel your pain, as I've very recently been there myself. :pouting_face: :pouting_face: :pouting_face:
It sounds like either a lot of gaskets have perished or not been fitted properly in the first place? Either way an overhaul of em all may be prudent???
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@Louis-James Well hopefully the only bumps you'll see from now on, will be the ones you are jumping over MX styleee!!!
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So the oil pump was not flowing. Took it off and the outlet was block. Removed the hose tail and I drilled the smaller bore. Oil now flows through.
Without taking the pump alart again I am unsure if I have drilled too deep and the oil is bypass internally. By blowing through it and operating the throttle.. it doesn't seem to flow more or less on throttle position. Does there need to be drive to the pump and is it a variable gear inside is what changes the flow?
So going to have to inspect.
Or compare to another.Also bike cuts out when put into gear with stand up or down.. I think it's a faulty sidestand switch
A few little things to sortAnyway.. a few pics
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Bike looks superb. Done an excellent job there. Definitely will be on that infamous hall of fame...
Yeah side stand switch is common on all bikes. Should be relatively simple to figure out.
Hopefully it's the switch and not the CDI.
Yeah pumps can be weird to diagnose, better run premix whilst you're figuring it all out!