Yosh! After much toil and back breaking effort my Japanese style build is done. Here is everything, I'll try to be as detailed as possible.
Headlight - I wanted a dual headlight and didn't see any in Marco's catalogs in Japan so I found this one at http://www.electrosport.com/electrosport_streetfighter.dual.html , it's a little pricy but it's the only one I could find that matched the proper voltage output for the tw. I used plumber's strap (painted with truck bed liner, big thanks to Steelfist for this one!) to mount it to the stock housing for the original headlight. Electrically it was super easy to install.
I removed the front fender completely and removed the stock fork boots in favor for fork plugs bought from Japan. Front fork was easy to get out once I realized I hadn't disconnected the front brake yet, doh!
The turn signals are also from Japan and instead of getting the aftermarket housing I simply mounted them to the stock headlight housing. Electrically these were a real pain and I blew 3 fuses before I get the correct connection. This was hard because the stock headlights come with 3 wires, were as the aftermarket came only with two and I think I did every wrong combination before I did the correct one.
Replaced the stock speedo with a km/h speedo from Japan which was also very easy to install and looks quite nice! As my bike only had 700 miles on it I'm not going to consider it cheating:)
I removed the gas tank, sanded it down a little and again applied truck bed liner paint. Then made myself a stencil and used standard outdoor spray paint to do the design.
Aftermarket seat from Japan. I actually like the comfort level of the old seat more, but it's to long.
Removed the stock airbox and replaced with k&n air filter. If you do this your going to have to remember to remove the stock rubber hose from the stock air box or the k&n filter won't reach.
130 jet from local yamaha dealer, $10. Get it, it's worth it. Stock is 126 but you can tell the difference. Make sure not to remove the clutch cable lever as it was a real bitch to get back on. Try to get into that carb without removing, it will be worth it!
Built a holder for battery out of plumber strap again. That stuff is super handy and strong! But you need tin snips to cut it.
Brake light and signals from Japan. Look great but having some issues getting the brake light to get brighter when I brake, if anyone has advice, let me know.
Aftermarket pipe and muffler from Japan. I think it sounds great. Very beefy sound.
Finally after market chain and swingarm from Japan. Came as a set and the funny thing was that I tought it would be a snap to put on because it's a set. But chain was to short. Then I realized from looking at the forums that the stock rear gear is 45 in Japan and 50 here in the U.S.. So I bought a 42t from JT on Ebay and that did the trick. The bike runs amazing now. I can get up to 20mph in first gear and I haven't tried top speed yet, but I'm guessing by the new gearing, paired with the jet, exhaust and air intake, that it's going to be around 70-75 easy.
If anyone has any question for me please don't hesitate to ask! Long Live the TW200!!!
The rig rides nice as spice that I want to say it twice...haha. I actually really like the knobbies on there, it's like a jeep on two wheels. Looks cool but tough.
If you don't like the longer swingarm then you should be happy I did't get the longer one, this is actually the shorter of the two you can get from Japan!
Steelfist rides again! I agree the stock seat is way more comfy but it's to long for my taste. I really need to get some of those alternator things for the tail light, I'm feeling a little dangerous right now. I greased up the rod as I slide it through (oh la la) so I'm not to worried about the grease points and I don't have the equipment to add them myself, but maybe in the future.
The trip does have a reset, it's on the side.
Really! That sucks, but if that's all there is to it that's ok. I'll give it a shot and hope I don't blow to many more fuses:)
Where did ya get those seals that go on the top of the forks, they look the goods. Nice work on the bike but if ya gonna use it as your everyday
ride get some road tyres they hold the corners much better in the wet ( dont ask me how I know). P
I got the fork seals from Marco in Japan. But I do remeber seeing them on ebay as well for the same price $18. If you do need something from Japan you can see pics here:
http://www.flickr.com/photos/jdmtw200/
Thanks for the compliment:)
The new swingarm is about 2.5 inches longer then the old one. I got it from Marco in Japan, great guy. If you want to take a look at his catalog and email you can see them here:
http://www.flickr.com/photos/jdmtw200/page2/
And I got the shorter of the two he has listed.
ryanmm,
just a couple more quick questions . how much is the swingarm, which one is it(i couldn't tell from the catalog, if you have a style number, that would be great), and then did you have to buy a longer rear brake connecting rod? thanks for your help.
It was $550 for the swingarm, the yen is stronger then the dollar, so everything is kinda pricy unfortunately, but it did come with the chain and an extender for the brake connecting rod.
If you go to the second page of the photos the caption above the picture is TW200 Extended Swingarm, catalog number is 207-073.
thanks for the info.
great job !
best looking jap build ive seen so far .
clean and finished look .
real eye catcher .
love it .