MY TW200 Custom

[MIK20B]

hi guys, new to the forum, made the donation and waiting to get access to the full member yamaha area, but thought id post this here anyhow... hope you all like it.

I got this yamaha TW200 farm bike off my uncle for pretty cheap.

http://img135.imageshack.us/img135/8781/thechunkeyac8.jpg

after a bit of net searching, i found they are a popular bike to customise over seas, and theres even a shop here in sydney that builds them, and sells them for pretty big money...

heres some of the ones i found on the net, that inspired me to start on it.

http://img512.imageshack.us/img512/3586/chunkey2zd1.jpg

http://img266.imageshack.us/img266/5395/chunkey3jg7.jpg

http://img135.imageshack.us/img135/4468/chunkey4lt2.jpg

They look pretty tuff, and i decided to do the same thing to my bike, useing my own ideas and colour schemes..

After i showed Dave at restoremaz the pics of the modified ones, he was very excited about the whole thing,and offered to help.. and sugested we start right away.

so it began..project chunkey monkey!! The original print in the yamaha tw200 brochure says its a "chunkey monkey"...so the name has stuck.

Ok, here it is just minutes before the strip down....and Dave and i all keen to get started..



http://img261.imageshack.us/img261/6858/chunkey1lk9.jpg



Striping the bike down...it dosnt take to long, but we took heeps of photos of every single part, and where it goes.....its important to do this, its a great help apon reassembly if you forget where something goes.

http://img355.imageshack.us/img355/1305/chunkey5mb4.jpg


Couple of hours later....not much left.

http://img247.imageshack.us/img247/1773/chunkey6np6.jpg



next task was to extend the swing arm. Most of the moded bikes have had this done, it makes them look better, and gives the bike a longer wheel base.
we decided about 5 inches was enough...and went down to see Ross at mr enforcer engineering.

he sugested choping it, then inserting steel tube of the same shape inside the swing arm for strength, then welding caps over it to bring it back up to the normal thickness.

Cut and test fitting here...

http://img148.imageshack.us/img148/6504/chunkey7pg8.jpg

http://img511.imageshack.us/img511/4299/chunkey8qk4.jpg

http://img148.imageshack.us/img148/5184/chunkey9kq2.jpg

trial fitted to the bike here, to see how it looks....

Already looking tuff!! :thrust:

http://img511.imageshack.us/img511/6412/chunkey10hq6.jpg




After we were happy with how it was all looking, we finished striping it down, and sent the frame away to be sandblasted.

when it came back, we ground off any brackets and mounting points we didnt need.
we worked out which ones were to go before stripping the bike down, and marked each one with a small hacksaw blade cut.

grinding brackets off...

http://img384.imageshack.us/img384/9331/chunkey11xf7.jpg

Next step was to etch primer the frame and get it ready for paint....


http://img384.imageshack.us/img384/3608/chunkey12uv7.jpg

http://img384.imageshack.us/img384/1028/chunkey13ki0.jpg



Ok frames painted here.......decided to go with a gold basecoat.....im very happy with the colour...

http://img261.imageshack.us/img261/8971/chunkey14jn3.jpg




Next we started on the motor.

We had got it running before we striped the bike. it had been sitting round for a while, and the carby was all jamed up with crystalized fuel and junk...we got it to run pretty good, but the only problem we found was the clutch was rubbsih. it was slipping pretty bad..so i ordered new clutch plates from yamaha.
we also detailed the motor as best we could.....


http://img390.imageshack.us/img390/7640/chunkey15zt5.jpg

Striping motor down..

http://img525.imageshack.us/img525/324/chunkey16va9.jpg

Painted up ......we kept the cooling fins in the alloy look....


http://img385.imageshack.us/img385/6019/chunkey17et3.jpg



New clutch plates..

http://img361.imageshack.us/img361/3555/chunkey18vo6.jpg

http://img162.imageshack.us/img162/9454/chunkey19qf3.jpg

http://img361.imageshack.us/img361/7927/chunkey20yr5.jpg

Puting clutch back together and fitting new drive sproket...

http://img162.imageshack.us/img162/9713/chunkey21gv6.jpg

http://img162.imageshack.us/img162/2630/chunkey22yu1.jpg



We driped red paint into the "yamaha' lettering on the side of the engine....it took a bit of time, but it came out good.....

http://img361.imageshack.us/img361/6610/chunkey23rn2.jpg


motor looking fresh..ready to go back onto the frame.

http://img361.imageshack.us/img361/3452/chunkey24iy8.jpg


Ok, motor bolted back onto the frame here....with starter motor and coil .

http://img211.imageshack.us/img211/9505/chunkey25rw8.jpg

http://img211.imageshack.us/img211/6264/chunkey26qk1.jpg

The side stand, engine bracket and doubeling pegs needed to be sandblasted and repainted.


http://img235.imageshack.us/img235/283/chunkey27pk6.jpg

http://img235.imageshack.us/img235/5152/chunkey28lq5.jpg

http://img387.imageshack.us/img387/3819/chunkey29yq9.jpg



Next step was the battery holder/standard air box.
i didnt want that big and bulky box and air filter unit to spoil the bike, so i trimed it all down, and just left enough of it to suport the battery.
we replaced the standard air filter with a small one, and hid all the wireing up under the seat.

This is how it looked before.

http://img357.imageshack.us/img357/7757/chunkey30wy8.jpg

triming it down, and fileing down all the edges...

http://img353.imageshack.us/img353/5784/chunkey31lx9.jpg

Nice and small now, and all wireing tucked away under the seat.

http://img353.imageshack.us/img353/4594/chunkey32gi9.jpg

http://img353.imageshack.us/img353/147/chunkey33zd9.jpg


Next we sand blasted all the steering and triple clamp parts...painted them up, and fitted new steering head bearings.
We also got a bike mechanic to rebuild the front forks, and fit new fork seals....the front gaurd is an off the shelf item for these bikes from a place in the city.

http://img368.imageshack.us/img368/2478/chunkey34km0.jpg

http://img152.imageshack.us/img152/5896/chunkey35fu1.jpg

http://img368.imageshack.us/img368/8973/chunkey36ie6.jpg

http://img368.imageshack.us/img368/3696/chunkey37ks6.jpg

New steering head bearings..

http://img368.imageshack.us/img368/2786/chunkey373gp1.jpg

http://img368.imageshack.us/img368/1112/chunkey38nk1.jpg

Front gaurd and forks fitted here.

http://img363.imageshack.us/img363/308/chunkey39tr8.jpg



next we got the swing arm sandblasted, smoothed out the welds, did some bog work, and painted it up, and fitted it back to the bike...

http://img184.imageshack.us/img184/9854/chunkey40jd7.jpg

http://img378.imageshack.us/img378/1387/chunkey41aj9.jpg

http://img378.imageshack.us/img378/8236/chunkey42gq4.jpg

http://img381.imageshack.us/img381/3416/chunkey43lg6.jpg

http://img378.imageshack.us/img378/9996/chunkey44zw5.jpg

Starting to look like a bike again now.......new handle bars painted and fitted here to...

http://img378.imageshack.us/img378/1272/chunkey45tn9.jpg



Fuel tank time........
paint striping it down, repairing the dents and geting it ready for paint.

http://img368.imageshack.us/img368/3990/chunkey46lk2.jpg

http://img368.imageshack.us/img368/3179/chunkey47ds0.jpg

Back to bear metal....

http://img210.imageshack.us/img210/1276/chunkey48db1.jpg

old fairing tabs removed, we will not be refitting any of the side panels.....

http://img368.imageshack.us/img368/5268/chunkey49cv8.jpg

Nicky work done here, ready for primer....

http://img210.imageshack.us/img210/8200/chunkey50om8.jpg

http://img210.imageshack.us/img210/6440/chunkey51jh8.jpg

primered...

http://img353.imageshack.us/img353/9062/chunkey52qn1.jpg

Here it is painted.......i chose satin white

http://img353.imageshack.us/img353/5829/chunkey53tf7.jpg




geting there now.

some new parts, a new rear LED tail light...some smaller carbon fiber look blinkers, new handle grips and all of the axles and brake parts and chain adjusters freshly silver zinc coated.

http://img525.imageshack.us/img525/6280/chunkey54ph1.jpg

http://img387.imageshack.us/img387/4834/chunkey55wc6.jpg

http://img211.imageshack.us/img211/7162/chunkey56nk4.jpg



Time to get the bike rolling now.....

Rear tyre had a slight hit, so we heated it up, and panel beated it out till it was round again.....
painted up the wheels black, to give it that motard look, and fitted nice thick road tyres....they cost a pretty peny to :shock:

http://img522.imageshack.us/img522/1889/chunkey57lr1.jpg

http://img387.imageshack.us/img387/8687/chunkey58sn6.jpg

Bike rolling here.......tank fitted, along with handle grips,. brake and clutch leavers.

http://img360.imageshack.us/img360/3704/chunkey60qf3.jpg

http://img514.imageshack.us/img514/8321/chunkey59if3.jpg


Exhaust was pretty much the last thing.
i bought some bends, and a muffler off one of those pit bikes...
we used the front flange part off the original exhaust, mounted the muffler underneath the bike, then joined it all up.

http://img223.imageshack.us/img223/9344/chunkey61hg5.jpg

The mounting bracket on the muffler was in the wrong spot for the way we wanted to mount it, so we got Ross from enforcer to tig weld it into the spot we wanted...

http://img210.imageshack.us/img210/7103/chunkey62vl5.jpg

original pipe and flange cut off...

http://img396.imageshack.us/img396/2845/chunkey63mt2.jpg

http://img396.imageshack.us/img396/9892/chunkey64xr8.jpg

Tacked all into place before welding....

http://img266.imageshack.us/img266/668/chunkey65uy9.jpg

Back off the bike, and Dave welding it all up....

http://img396.imageshack.us/img396/8346/chunkey66tk6.jpg

well thats pretty much it. i just have to heat wrap the exhaust, and im still waiting for the new twin head light to turn up....
ive just put the original one on for now, but ill post pics of the new one as soon as its fitted.

here she is all finished and registered.
just have to get the carbie jeted and tuned, and ill be cruising round on it =D>

Ill also be retrimming the seat in white when the trimer reopens for the year...


http://img165.imageshack.us/img165/8338/chunkey67ed2.jpg

http://img165.imageshack.us/img165/3676/chunkey68vg5.jpg

http://img223.imageshack.us/img223/9890/chunkey69km5.jpg

http://img223.imageshack.us/img223/3686/chunkey70zy9.jpg


want to turbo it now, got a IHI RHB31 turbo, you think it will work? suck through carby turbo set up... just for the look and the sound, not really for performance yet...

[Weaselman]

Deus Ex Machina can go fuck itself good work you lot

[latheboy]

That has radness all over it....

Welcome Michael....

[damo1]

Mate welcome and what an awesome thread for your firts one.;)

I love the build and now it's worth about 20k if you beleave deus.

The only thing that i would have done different is the exhaust, i would have run it down closer to the engine at the front rather than have it sticken right out like that.

Other than that very nicly done mate.

[MIK20B]

thats the only thing i dont like too... but the place didnt have 2 45 deg bends, and i wanted it going so setteled for the 90... hope to fit a turbo soon, so it wont be there for long!

[El_Hefty]

fucking sweet work, i must say ive admired the Dues bikes but hated the prices... which youve proven are bollocks

Welcome

[Benz]

Great first post Mik20B
A very original and well executed build mate. I'm also of the opinion that exhaust needs to be closer to the engine/frame. You know if you cut a 90deg bend in the middle, you have 45 degs..........

[MIK20B]

we didnt think of that... we were in a hurry to get ti going by then but!

[DiscoDan]

Top job, what an entrance! I've always wondered how those things handle with the extended swingarm and baloon tyres, let us know how it rides

[fimpBIKES]

i LOVE these things
particularly in the jap-style you've gone for


there are HEAPS of aftermarket upgrades in the super-autobac stores over there if you know anyone heading over

those tyres, checked the price on em a while back about $500 a pair isnt it???


LOVE IT, welcome!

[TurboKat]

Very cool bikes them [:p]
Good job on the rebuild, +1 on the exhaust (looks all wrong) & if it was mine, I'd either put some sort of stubby chrome guard on the back or take the front one off.
Put up some wheelie pics.

[MIK20B]

thanks guys, mucho appreciatedo!

yeah i know, the exhaust, the exhaust! wont be there for long... like i said, got the little turbo to go on there, just need some info on oil pumps and what ever else i need to fit it all up...

http://img24.imageshack.us/img24/9123/image1175.jpg

http://img23.imageshack.us/img23/5663/image1176.jpg


the tyres werent $500, but they werent cheap either!

[damo1]

Mate you need to speak to guys like Iceman,Deano,Exben.

Iceman turboed his GS500

Deano is currently Turboing his 7/12

And Exben has turboed every thing he can get his hands on.

And i'm sure there's more guys out there that could help but try these guys first.

Exben has probably forgotten more than most will ever even know so probably a good place to start.

Looking forward to seeing where you go next with this.

Good luck mate

[latheboy]

Singles dont turbo that well, but fuck it do it anyway....

[MIK20B]

oh really? how come? pulsing of the single piston?

[Gix11]

Welcome aboard Mik.
Excellent work by the way and one of the best intro posts to date! - good on ya!

[el sammo]

arrghhh pics arent workin for me? sounds cool as hell though haha

[gumby190]

Nice Job.

Those tyres are pretty full on, reckon they would make for interesting riding. Looks comfy though.
How quick she go? always been curious since I first saw one.





Glad you kept it, even though I was tempted.........
http://cgi.ebay.com.au/Yamaha-TW200-Custom_W0QQcmdZViewItemQQ_trkparmsZ65Q3a13Q7c66Q3a 2Q7c39Q3a1Q7c293Q3a1Q7c294Q3a50QQ_trksidZp3286Q2ec 0Q2em14QQhashZitem45ece06139QQitemZ300326871353QQp tZAUQ5fMotorcyclesQQsalenotsupported

[gumby190]

If you want the woosh noise of a turbo...........
http://i.ebayimg.com/24/!BWkR6Hg!Wk~$(KGrHgoOKiwEjlLmDn3YBKYC9Ulo7Q~~_1.JP G


[:p]

[MIK20B]

haha, thanks, i needed the cash, but seems no one wants to part with theirs either? so its staying, i dod still need the cash but hahaha

like ive mentioned, im by no means a good rider and i donr push it hard, but it seems to behave good enough for me. i have had other bikes before, RD250, RGV, GSXR600, and a heap of trail bikes... this behaves as good as all of them... and yes its comfy!

[Fight_fan]

Dude that is fuckin awesome! Well done hey!

[gumby190]

How long it take you to get it all together???

[MIK20B]

thanks alot guys

it took about 3 months i guess...

[scotty]

top job MIK

[Watto]

love it great job mate and welcome

[Benz]

Wicked little turbo, what make is it?[:p]
Singles aren't the best candidates for turbo's,
"oh really? how come? Pulsing of the single piston??"
You already know......

[JackTar]

This is inspiring, well fucking done mate.

[wackyrider]

nice one mate,
and welcome to the forum

[Elapid]

Very nice. Well done. Love the extended swingarm.

[80s freak]

fantastic build, welcome.