Yamaha TW200 rebuild

FJBen · 05-06-08, 09:32 AM

I just got (for free) an 87 Yamaha TW200 bike.

Very cool, same story, it did run but blah blah blah...

Anyways, it's at home and I've begun to start the repairs. Pulled the tank, it's leaking, I either need to seal or get a new tank.

At the moment I have no Spark. I've tried the old pull the plug, put it on the cylinder and kick it over but no fire. Even with the battery charger plugged in showing full juice, no spark. No electric start either, thats not working. When I check the coil I dont' have any power to it with key on. I would assume I should?

Now in the second picture, it shows I have power from the battery to this relay (assuming it's the starter relay) but none on the other side, which I shouldn't unless I'm trying to start.

Any other thoughts on where to go/start?

pics, the bike, wiring

pint · 05-06-08, 09:36 AM

Sorry, no help from me, but COOL bike! Good luck.

JJS · 05-06-08, 09:51 AM

Coil failure is pretty common on older 4-stroke Yamahas.

Hltoppr · 05-06-08, 09:54 AM

You might try searching and posting on Adventure Rider Motorcycle Forum It's kinda the IH8MUD of dual sporting....lots of info...

-H-

FJBen · 05-06-08, 10:00 AM

Cool, I'll check avrider, I've looked on there before.

I think I remember something about the coil failure. Anyone know how to test the coil?

Poser · 05-06-08, 09:57 PM

Ben-

Might want to try these folks out as well.

Good people and good info:

TW200 forum

FJBen · 05-07-08, 07:47 AM

Quote:

Originally Posted by Poser

Ben-

Might want to try these folks out as well.

Good people and good info:

TW200 forum

thatnks Poser, I found that yesterday. From the sounds of it, I think the neutral sensor may be causing some issues. I can use a screwdriver to jumper the starter relay and it turns over, just no spark.

I downloaded a FSM so I'll start the tear down into that.

NW-sickboy · 05-07-08, 06:28 PM

no help but i can say i have charged some insane single track trails on the 85-86 BW versions that were not road legal, we geared them down a a few teeth and could haul out quarter of an elk on the rear racks... ours ran ridiculously well for YEARS... great bikes.

I had to track this pick down.... we want on some pretty hairy single track with all of us on that rig... thinking this was taken in 93ish.. i am on the very back....

FJBen · 05-12-08, 07:58 AM

nice pics!

I got the bike started and running this weekend. Needs some adjustment here and there, but overall, I"m super happy!

FJBen · 06-13-08, 10:21 AM

thought I'd post an update...

Pro-Grip 791's
Tusk roost guards
New Oil and Filter
Seat is getting recovered
Rebuilt carb
Junkyard bar risers

Still need to do:
Baja Designs rear LED taillight
New Fork Seals
Seal Savers
New/used gas tank
New muffler

She's running pretty good, I haven't got to mess around too much yet because of the tank, (leaking slowly)

05-06-08, 09:32 AM	#1
FJBen Whitey Join Date: Apr 2004 Location: Greeley, Colorado TLCA# 15530 Posts: 2,287	Yamaha TW200 rebuild I just got (for free) an 87 Yamaha TW200 bike. Very cool, same story, it did run but blah blah blah... Anyways, it's at home and I've begun to start the repairs. Pulled the tank, it's leaking, I either need to seal or get a new tank. At the moment I have no Spark. I've tried the old pull the plug, put it on the cylinder and kick it over but no fire. Even with the battery charger plugged in showing full juice, no spark. No electric start either, thats not working. When I check the coil I dont' have any power to it with key on. I would assume I should? Now in the second picture, it shows I have power from the battery to this relay (assuming it's the starter relay) but none on the other side, which I shouldn't unless I'm trying to start. Any other thoughts on where to go/start? pics, the bike, wiring Attached Images __________________ ~~~~~~~~~~~~~~~~ 93 FJZ80 Slee 4"/OMEJ, 35's, 4.88's, ARB's, Metal Tech sliders, On Board Air, caster plates, DC drive shaft, Pin7, CDL, adjustable rear uppers, ARB front bumper, homemade rear, Slee Skid Plate, extended brakelines, backup camera 96 FZJ80 285's OME 's ride

05-06-08, 09:36 AM	#2
pint IH8MUD Addict Join Date: Jul 2005 Location: Parker, CO TLCA# 17493 Posts: 881	Sorry, no help from me, but COOL bike! Good luck. __________________ 2000 UZJ100, OME 865, OME T-bars, Slee Diff Drop, Slee Step Sliders, TJM T3, PowerStop Cross Drilled & Slotted Rotors, 295 Terra Grapplers M101 Trailer ridding on Nittos and green primer...

05-06-08, 09:51 AM	#3
JJS IH8MUD Lifer Join Date: Nov 2005 Posts: 1,841	Coil failure is pretty common on older 4-stroke Yamahas. __________________ '75 FJ40. V8. SOA. Cage. Lockers. Not done... "The FJ is Toyota's answer to the Jeep CJ, and flame wars between fanboys of the two vehicles will continue long after the apocalypse begins. The consensus is the Toyota will take more abuse -- a big plus when roaming the desolation -- but it's harder to fix when something goes sideways. Fortunately, it's a Toyota, so you'll break before it will."

05-06-08, 09:54 AM	#4
Hltoppr When In Doubt, Go Higher! Join Date: Aug 2002 Location: Port of Indecision...otherwise Northern Arizona Posts: 2,022	You might try searching and posting on Adventure Rider Motorcycle Forum It's kinda the IH8MUD of dual sporting....lots of info... -H- __________________ 2003 BMW R1150GS Adventure 1983 FJ45 Troopy KE7TYL ...and then there is always Mexico....

05-06-08, 10:00 AM	#5
FJBen Whitey Join Date: Apr 2004 Location: Greeley, Colorado TLCA# 15530 Posts: 2,287	Cool, I'll check avrider, I've looked on there before. I think I remember something about the coil failure. Anyone know how to test the coil? __________________ ~~~~~~~~~~~~~~~~ 93 FJZ80 Slee 4"/OMEJ, 35's, 4.88's, ARB's, Metal Tech sliders, On Board Air, caster plates, DC drive shaft, Pin7, CDL, adjustable rear uppers, ARB front bumper, homemade rear, Slee Skid Plate, extended brakelines, backup camera 96 FZJ80 285's OME 's ride

05-06-08, 09:57 PM	#6
Poser Oh...Durka Durka Durka. Join Date: Oct 2003 Location: in the shop TLCA# 1856 Posts: 13,949	Ben- Might want to try these folks out as well. Good people and good info: TW200 forum

05-07-08, 06:28 PM	#8
NW-sickboy lurker Join Date: Feb 2003 Location: utah.... for now Posts: 727	no help but i can say i have charged some insane single track trails on the 85-86 BW versions that were not road legal, we geared them down a a few teeth and could haul out quarter of an elk on the rear racks... ours ran ridiculously well for YEARS... great bikes. I had to track this pick down.... we want on some pretty hairy single track with all of us on that rig... thinking this was taken in 93ish.. i am on the very back.... Attached Images __________________ Tri4Life http://gdigitalborgsneed.blogspot.com/ Last edited by NW-sickboy; 05-07-08 at 07:12 PM.

05-12-08, 07:58 AM	#9
FJBen Whitey Join Date: Apr 2004 Location: Greeley, Colorado TLCA# 15530 Posts: 2,287	nice pics! I got the bike started and running this weekend. Needs some adjustment here and there, but overall, I"m super happy! __________________ ~~~~~~~~~~~~~~~~ 93 FJZ80 Slee 4"/OMEJ, 35's, 4.88's, ARB's, Metal Tech sliders, On Board Air, caster plates, DC drive shaft, Pin7, CDL, adjustable rear uppers, ARB front bumper, homemade rear, Slee Skid Plate, extended brakelines, backup camera 96 FZJ80 285's OME 's ride

06-13-08, 10:21 AM	#10
FJBen Whitey Join Date: Apr 2004 Location: Greeley, Colorado TLCA# 15530 Posts: 2,287	thought I'd post an update... Pro-Grip 791's Tusk roost guards New Oil and Filter Seat is getting recovered Rebuilt carb Junkyard bar risers Still need to do: Baja Designs rear LED taillight New Fork Seals Seal Savers New/used gas tank New muffler She's running pretty good, I haven't got to mess around too much yet because of the tank, (leaking slowly) Attached Images __________________ ~~~~~~~~~~~~~~~~ 93 FJZ80 Slee 4"/OMEJ, 35's, 4.88's, ARB's, Metal Tech sliders, On Board Air, caster plates, DC drive shaft, Pin7, CDL, adjustable rear uppers, ARB front bumper, homemade rear, Slee Skid Plate, extended brakelines, backup camera 96 FZJ80 285's OME 's ride

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