DT200WR restoration project pic heavy

[Louis-DT-WR]

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

[NINJA]

@Louis-James Did you not take any pics before you dismantled it???

[Louis-DT-WR]

@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.

[NINJA]

@Louis-James Well that's weird, maybe you have just discovered a fault before it ruined all your hard work???

[Louis-DT-WR]

@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.

[finnerz89]

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.

[Louis-DT-WR]

@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

[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

[Louis-DT-WR]

@NINJA thanks for that the link has the manual. Hopefully sort it tomorrow

[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???

[DTR+NSR]

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

[Louis-DT-WR]

@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

[NINJA]

@Louis-James A bullet dodged there dude!!! :thumbs_up_light_skin_tone:

[Louis-DT-WR]

@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.

[NINJA]

@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???

[Louis-DT-WR]

@NINJA always when someone else does work

I've thoroughly checked all over. The top end had been rebuilt with a wiseco piston.
I did check that.

But one of the last bits done to the engine was a new clutch and water pump seal.

[NINJA]

@Louis-James Well hopefully the only bumps you'll see from now on, will be the ones you are jumping over MX styleee!!!

[Louis-DT-WR]

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 sort

Anyway.. a few pics

[Calum]

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!

[Louis-DT-WR]

@Calum thanks a lot man.

It didn't have a side stand switch before.
It was looped (wiring present) but I bought a universal switch. I'll do a circuit test on it.

Yes I'm running premix arm. Engine is sweet!
No leaks!