Yamaha TW200 Trailway Discussion Forum

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03-01-2010, 10:10 AM smthng Joined on 03-01-2010 Florida for now Posts 29 Bringing it back? Hey all, I snagged a 2003 TW-200 with just under 2000 miles on it. Unfortunately, the PO flogged it and aparently has no idea what the word "maintenance" means. That raises a few questions as I try to bring it back from "near-dead". The clutch is shot. How evil of a job is it on this one? I have the service manual, is there anything funyk I need to be aware of, any special tools that are absolutely required? The chain is stretched out quite a bit. I adjusted the slack so I can at least run it without jumping the chain, but I can pull enough off the rear sprocket to see under the chain. I know I need a new chain, but should I plan on front and rear sprockets too? They don't look too bad, but without having a decent one to compare to, I can't really tell how worn they are. There's a pretty bad chatter from the top end somewhere at speed or when I give it a lot of gas. It's definately RPM related and it sounds kind of like a valve, but not like any other thumper I've had. Is it possible I need to adjust the cam chain tension, or should I just expect it to be an exhaust valve? Is there anything else I should tackle at the same time, since I'll have the thing cracked open anyway? Finally, the idle speed keeps dropping the longer I run it. I keep adjusting it, but then it's all but screaming the next time I start it cold. Is this a common problem and is there a common fix? Even with it's issues, the TW was a good price and a ton of fun. At least it doesn't burn oil! :) Thanks in advance for any input! --smthng 2003 TW-200, 2006 & 2009 Jeep Unlimited Rubicons, 2001 Dutch Star 38' RV.    Report

03-01-2010, 12:35 PM rodrey Joined on 05-14-2009 Simi Valley, Ca Posts 744 Re: Bringing it back? Attachment: tw%20056.jpg Welcome. You might want to use the search function to find specific detailed info on your questions. In general: Clutch is not too bad of a job. Pretty much like any dirtbike. They are kind of wimpy, and failure is common, but not at 2,000 miles. If the chain is as bad as described, likely both sprockets should be changed also. Front one is a bit of a pain. Use the search function to find a write-up. Top end chatter is probably just valve adjustment, and or cam chain adjustment. Pretty easy. It could possibly be cam damage due to oil starvation. Not uncommon on an abused bike, and a pretty big job. Usually requires replacing the cam & head. Hard to tell about the idle. Do a tune-up & clean the carb, change the oil, & see where you are after that. You have a very low mile engine. Likely still has the factory oil in it. A fried clutch after only 2k miles says it was thrashed pretty hard. Good luck! TW-less for now... Proud Dad of a Marine 3 1/2 gallon Clarke tank Banshee rear shock XT250 forks 21" front rim XT250 speedo cluster XT225 kickstand Duro Power Grip ATV tire Opened up exhaust CRF 450 handlebars GPS bar mount    Report

03-01-2010, 3:50 PM smthng Joined on 03-01-2010 Florida for now Posts 29 Re: Bringing it back? Pretty much what I figured with the clutch.  Do I need the Yamaha Genuine Clutch Plate Puller/Holder, or can I finagle some other reasonably common tool to handle the job? I'll just plan on replacing the sprockets...  I hate burning up a new chain on old sprockets anyway. The oil actually looks pretty good... it's golden, not black.  Of course, that could mean the PO just did the only change it ever had right before he sold it to me.  I'll run up to the stealer and get a filter and change the oil anyway.  That's a couple bucks for decent insurance, IMO.  Yes, he thrashed it.  Wouldn't surprise me in the slightest to find steel-on-steel when I open up the clutch cover. :S  Still, it's in good enough shape that I think it'll come right back to life once it's had some care.  I'm letting a good Seafoam treatment tackle the carbs... I'll do some hand cleaning and jetting if that doesn't do it.  Thanks! --smthng 2003 TW-200, 2006 & 2009 Jeep Unlimited Rubicons, 2001 Dutch Star 38' RV.    Report

03-01-2010, 5:36 PM QWERTY Joined on 11-22-2006 Posts 2,360 Re: Bringing it back? Oil, filter, tune-up is a good start. The carb is a realtively simple one. A couple spray cans of carb cleaner, the instructions on this site, and a couple hours will take care of a host of gremlins. While you have the carb apart slip a flat washer under the clip on the needle to raise it a bit and set the pilot screw to 2.5 to 3 turns out. Clean the petcock while you are at it. 2000 miles on the stock chain without maintenance and it is beyond toast. O-ring chain and new sprockets--best bang for the buck. The clutch requires no special tools. Pretty typical low-tech mechanical clutch. Barnett makes plates and springs, a bit priocey but well worth it. The Yamaha steels are excellent.    Report

03-01-2010, 6:28 PM rodrey Joined on 05-14-2009 Simi Valley, Ca Posts 744 Re: Bringing it back? The only special tool recommended is to hold the basket from turning when removing the bolt. I use an impact gun, no tool required. TW-less for now... Proud Dad of a Marine 3 1/2 gallon Clarke tank Banshee rear shock XT250 forks 21" front rim XT250 speedo cluster XT225 kickstand Duro Power Grip ATV tire Opened up exhaust CRF 450 handlebars GPS bar mount    Report

03-02-2010, 7:30 AM rodrey Joined on 05-14-2009 Simi Valley, Ca Posts 744 Re: Bringing it back? Attachment: imgp0517.jpg When you have the clutch apart, check the basket & hub for grooves worn by the plates. It will cause the clutch to slip or be notchy. The grooves can be filed smooth if they are not too bad. I've seen these where the plates were good, but the basket & hub were worn. Not TW, but same idea: TW-less for now... Proud Dad of a Marine 3 1/2 gallon Clarke tank Banshee rear shock XT250 forks 21" front rim XT250 speedo cluster XT225 kickstand Duro Power Grip ATV tire Opened up exhaust CRF 450 handlebars GPS bar mount    Report

03-02-2010, 11:17 PM Petrus Joined on 06-17-2008 Cape Town, South Africa Posts 118 Re: Bringing it back? I`ve seen a local TV show in which they replaced the clutch of a TW recently. They did it in a field - to show how easy it is. + the grass would not damage the bike like a hard surface would. I`ve never done it myself, but the guys did the following that I can remember: Lay the bike left side flat on the ground (the side with the gear leaver) They removed the side cover - the one thats on the same side as the kick start. They removed the clutch plates and replaced them with oiled new ones. Reassembled everything, started the bike and off they went. This was done very quickly. This is probably the way they do it in enduro races ???? They did NOT drain the oil - I presume that`s why they layed the bike down on its side. There was no spills. 2008 Yamaha TW200 Honda XR500R Honda CL90    Report

03-04-2010, 12:14 PM smthng Joined on 03-01-2010 Florida for now Posts 29 Re: Bringing it back? Thanks for the post on what to look for on those teeth...  I'll see what condition it's in when I yank it apart.  Probably be about a week or so before I can dig into it.  From all the descriptions so far, it looks like pretty standard stuff.  A few days with wrenches and we should be good to go. Thanks all! --smthng 2003 TW-200, 2006 & 2009 Jeep Unlimited Rubicons, 2001 Dutch Star 38' RV.    Report

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