Yamaha TW200 Trailway Discussion Forum

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03-05-2010, 6:31 AM MMMOTORCYCLE Joined on 08-20-2007 Posts 18 Exhaust cap screw Im trying to remove the exhaust tip and the phillips head screw wont budge....PB Blasted it, heated it, smacked it with a hammer I don't want to strip the head, any suggestions?? Mike    Report

03-05-2010, 6:42 AM rodrey Joined on 05-14-2009 Simi Valley, Ca Posts 744 Re: Exhaust cap screw An impact driver (the knid you hit with a hammer) is about your only other option. 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

03-05-2010, 6:43 AM tw1994 Joined on 06-30-2009 Stockton Ca. Posts 191 Re: Exhaust cap screw If you have access to a welder tack an old allen wrench to it and then replace it with a bolt or an allen head, or drill it out. I have had some luck clamping a vicegrip to the head of the screwdriver and slowly turning it while putting my full weight on the back of the driver ( make sure to go against the clock LOL ) Good luck. The Dutchman, Stockton Ca 2001 Dyna Superglyde 2006 Honda Rancher 4x4 1994 TW200 2008 Starcraft 34RT 1994 F250 powerstroke/Lance LC480-9.6    Report

03-05-2010, 8:52 AM BillMichaels Joined on 08-27-2006 SF Bay Area Posts 474 Re: Exhaust cap screw Don't forget the Anti-Seeze on the old pipe and new bolt. BillMichaels '98 FLHTC 03 Electric BladeZ 04 TW 200 04 TW 200    Report

03-05-2010, 4:54 PM dot1452 Joined on 06-10-2007 Ephrata, WA Posts 269 Re: Exhaust cap screw Drill it out, buy a new one, install a hex or allen head bolt, and put on some anti-seize. Thats how I did mine. Even with the screw removed I couldn't get the spark arrestor off. I destroyed it trying to remove it. If you can't find it, grind it.    Report

03-05-2010, 9:07 PM MMMOTORCYCLE Joined on 08-20-2007 Posts 18 Re: Exhaust cap screw OK, so an impact driver worked. But now the end cap (spark arrestor) will NOT budge!! I've used 1/2 can of PB Blaster. What gives? I've scratched the hell out of the cap when the vise grips slipped...DAMN! Any tricks on removing the end cap? Thanks Mike    Report

03-06-2010, 4:47 AM dot1452 Joined on 06-10-2007 Ephrata, WA Posts 269 Re: Exhaust cap screw You are in the same boat I was once in. Mine wouldn't move either. I destroyed mine getting it off. Friction is the only thing holding it on. Try an oil filter wrench. I finally had to cut mine in pieces. Luckily a new part isn't too expensive, but I hated to buy it. If you can't find it, grind it.    Report

03-06-2010, 6:51 AM Robert B. Lamar Joined on 08-19-2008 Mount Juliet TN. Posts 206 Re: Exhaust cap screw Doe's the arrestor get bad enough that it needs to be cleaned often? I gave mine a quick try once and did not resort to heavy handed tactic's to get it off. Just wondering if I should bother since I don't have a rattle or any indication that it needs servicing yet. Brad Lamar 2006 TW200 Moose Bark Busters Tusk Risers Ricochet Skid Plate IMS SS Pegs Stearns Seat Pad 1990 Honda Pacific Coast    Report

03-06-2010, 8:14 AM dot1452 Joined on 06-10-2007 Ephrata, WA Posts 269 Re: Exhaust cap screw <BLOCKQUOTE><table width="85%"><tr><td class="txt4"><img src="/Themes/default/images/icon-quote.gif">&nbsp;<strong>Robert B. Lamar wrote:</strong></td></tr><tr><td class="quoteTable"><table width="100%"><tr><td width="100%" valign="top" class="txt4">Doe's the arrestor get bad enough that it needs to be cleaned often? I gave mine a quick try once and did not resort to heavy handed tactic's to get it off. Just wondering if I should bother since I don't have a rattle or any indication that it needs servicing yet.</td></tr></table></td></tr></table></BLOCKQUOTE> Good question. I got my 1990 used with about 3500 miles on it. I don't know if the spark arrestor had been removed, cleaned, or replaced. It didn't look like it was messed with (no marks on screw holding it in) so I decided to take it out to clean it. It wouldn't come off, so I ordered a new one and cut the old one off. It was clean as could be. Nothing in it. I thought I would knock out some soot or something, but nothing. If you can't find it, grind it.    Report

03-06-2010, 10:42 AM MMMOTORCYCLE Joined on 08-20-2007 Posts 18 Re: Exhaust cap screw Finally got it off with the pursuader (rubber mallet) but it doesn't look pretty. Anyhow, the spark arrestor was completely rusted and broken in 2 pieces. I guess I could buy a new spark arrestor/end cap $55 or is there a way to replace just the spark arrestor? I have seen just the screen for sale $12-30, cut the old off and insert maybe? Suggestions?    Report

03-06-2010, 10:41 PM jclovesu Joined on 06-22-2006 Madras, Oregon Posts 610 Re: Exhaust cap screw $41.09 at Boats.net.  I know that is still a lot for what it is, but hey $14 in your pocket instead of the stealership. Tim Cyclerack, Richchet Skidplate, Tusk Bar Risers, Tusk Hand guards, UFO Raised Fender on Custom bracket, Custom Seat, D2 Pegs, DURO ATV Tire, Maxxis 6006 Front Tire, DID O-Ring Chain, Walmart Cooler tail bag, Ken Sean folding mirrors, Pro Grips.    Report

03-07-2010, 8:55 PM SpudRider Joined on 07-18-2008 Idaho Posts 244 Re: Exhaust cap screw  MMMOTORCYCLE wrote: Finally got it off with the pursuader (rubber mallet) but it doesn't look pretty. Anyhow, the spark arrestor was completely rusted and broken in 2 pieces. I guess I could buy a new spark arrestor/end cap $55 or is there a way to replace just the spark arrestor? I have seen just the screen for sale $12-30, cut the old off and insert maybe? Suggestions? You also have another, low-cost option.   For $101.94, you can buy a new, FMF, Turbine Core 2, spark arrestor/silencer from OEM Cycle.   The 1.25-inch model designed for 200cc-500cc machines is the version you want.  If your total order equals $125, you will receive free shipping. http://www.oemcycle.com/Item/product/326/ The Turbine Core 2 is a U.S.F.S. approved silencer, as well as a U.S.F.S. approved spark arrestor.  I have the Turbine Core 2 installed on my Zongshen 200GY-2, and several TW200 owners have installed it also.  The Turbine Core 2 weighs less than the stock muffler, and is also much better looking. Spud Vox populi, vox dei.    Report

03-08-2010, 5:38 AM MMMOTORCYCLE Joined on 08-20-2007 Posts 18 Re: Exhaust cap screw Spud, I have an FMF exhaust and header on my DRZ and have to keep a close eye on the db level. I ride AMA events and I have to pass the sound tests. Anyone have this exhaust sound tested on the TW? Mike    Report

03-08-2010, 9:21 AM SpudRider Joined on 07-18-2008 Idaho Posts 244 Re: Exhaust cap screw  MMMOTORCYCLE wrote: Spud, I have an FMF exhaust and header on my DRZ and have to keep a close eye on the db level. I ride AMA events and I have to pass the sound tests. Anyone have this exhaust sound tested on the TW? Mike If you do a search for "Turbine Core," you will find several members of these forums who have installed the FMF, Turbine Core 2.  In fact, I got the idea to install mine after reading a thread posted by another forum member, Jefmtbkr. http://tw200forum.com/forums/22268/ShowPost.aspx My Turbine Core 2 has a nice, throaty sound, but it is not too loud. According to all reports I have read, the Turbine Core 2 is much quieter than the FMF, Powercore 4 muffler. The Turbine Core 2 is quiet enough to be a U.S.F.S. approved silencer (94 db).   I have ridden about 5,000 miles with the Turbine Core 2 installed on my Zong, and it still sounds great!  I don't think I will need to repack this silencer for many more miles. Spud  Vox populi, vox dei.    Report

03-12-2010, 7:30 PM MMMOTORCYCLE Joined on 08-20-2007 Posts 18 Re: Exhaust cap screw Thanks for the info on the FMF. Correct me if Im wrong (its happened before according to my wife) the USFS approval is the "spark arrestor" not the silencer/94db level? Also, I can't find a Turbine 2 for the TW200. Did you fit another model like an XT225? I got the carb rejetted (Mikuni 130) and 0.050 spacers on the needle and 2 3/4 turns out on the idle. We live at about 800' msl...seat dyno says it was worth it! Thanks Mike    Report

03-12-2010, 9:47 PM SpudRider Joined on 07-18-2008 Idaho Posts 244 Re: Exhaust cap screw  MMMOTORCYCLE wrote: Thanks for the info on the FMF. Correct me if Im wrong (its happened before according to my wife) the USFS approval is the "spark arrestor" not the silencer/94db level? Also, I can't find a Turbine 2 for the TW200. Did you fit another model like an XT225? I got the carb rejetted (Mikuni 130) and 0.050 spacers on the needle and 2 3/4 turns out on the idle. We live at about 800' msl...seat dyno says it was worth it! Thanks Mike You're welcome.   The U.S.F.S. approves both the spark arrestor, and the sound level for this silencer.  I bought the universal spark arrestor that fits the 1-1/4 inch exhaust header. Spud Vox populi, vox dei.    Report

03-14-2010, 4:51 AM MMMOTORCYCLE Joined on 08-20-2007 Posts 18 Re: Exhaust cap screw What pipe did you use? XT225 header with the FMF pipe?    Report

03-14-2010, 10:18 AM SpudRider Joined on 07-18-2008 Idaho Posts 244 Re: Exhaust cap screw  MMMOTORCYCLE wrote: What pipe did you use? XT225 header with the FMF pipe? Yes, I bought a stainless steel, XT225 exhaust header on eBay.  However, other members of this forum have used the stock, TW200 exhaust header. Spud Vox populi, vox dei.    Report

07-06-2010, 1:02 PM Lone Wolf Joined on 07-01-2010 Knoxville, TN Posts 11 Re: Exhaust cap screw I cleaned my spark arrestor a few days ago and found that it was a real pain to remove even with just 1000 miles on the bike.  I managed to get the screw out without too much hassle, but the arrestor would not budge.  It took beating it with a rubber mallet for about a half an hour to break it loose.  The main problem I see with the design is that Yamaha paints the muffler fully assembled, so, the entire area under the spark arrestor is bare metal and rusts terribly.  That's why there are so many TWs out there with rusted out mufflers.  I stripped the rust off my spark arrestor with an overnight acid dip and repainted it inside and out with a quality ceramic exhaust paint.  I also cleaned up the unpainted end portion of the muffler and painted it.   Before I reassembled, I put some graphite brake caliper slide grease (good to 600+ degrees) all around the mating surfaces.  I also replaced the rusty screw with a stainless allen bolt with anti seize on it.  Hopefully,  it will be easier to service next time. Joel ____________________________________ 2009 Yamaha TW200 - Stock (for now) 2009 Honda Rancher 420AT - Decked out for trails 1984 ATC70 - Stock 1984 ATC70 - Basket case restoration in progress 1986 TRX70 - Stock    Report

07-07-2010, 12:39 PM trailz_rider Joined on 04-24-2008 BFE Posts 290 Re: Exhaust cap screw I've take 3 of them off using Freeze-Off and they come right out without having to use an impact driver.    Report

07-07-2010, 7:56 PM johnnyro Joined on 04-30-2010 White Mountains NH Posts 54 Re: Exhaust cap screw Loosened my arrestor with philips screwdriver inserted into screw hole and hammer that backwards. Broke it free. I remember an open ended wrench wiggled into it somehow but cant remember exactly how, hammered that too. Came right off. Gooped it up for reassembly. Cosmetics undisturbed. My 2006 had 1600 miles. Screw came out with mild heat and pliers on screwdriver. Didn't have to escalate.    Report

07-12-2010, 6:43 PM awjeez Joined on 08-13-2006 PNW Posts 321 Re: Exhaust cap screw Agreed on using anti-seize on any exhaust bolts. Preferably the copper based stuff if you can find it. Doesn't burn off as quick.    Report

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