Project TS200RT Tidy Up

Section59 · Spanner Monkey Joined: 05 Apr 2005 Karma :

Now then peoples. First project, first project thread.

Not used to doing this kinda thing and am as useless as anything when it comes to mechanical stuff, so go easy on me. I figured if i had some people watching what im doing, it might make me pull my finger out and get this fucker sorted, instead of it forever being in the shed in bits.

Also hoping some of you guys can help me with the many problems im sure to have also.

Plans are :

Source a top end kit, piston, rings, wrist pin, circlips, little end bearing, which is seeming easier said than done!

Redcar suzuki quoted me £150 just for the piston and rings! Shocked

Might have sourced rings and piston from germany for considerably less though if it pans out, just waiting on the seller to get back to me.

Get frame and swingarm powdercoated gloss black, might get the yokes done also but that would mean getting the stem pressed out and new head bearings, right?

Tank, tank side panels painted gloss black, new front and rear mudguards, and somehow tidy up the side panels as they're scratched to buggery. Basically i just want to tidy it up as best as i can for as little as poss and also learn a bit more about the mechanicals in the process.

Heres a few pics of how it looked until i started stripping it, will update with pics tomorrow with current progress.

https://farm7.static.flickr.com/6197/6106434323_15ba91ba0c.jpg

https://farm7.static.flickr.com/6193/6106434065_4aac3e40fb.jpg

https://farm7.static.flickr.com/6071/6106433869_5f1b10172a.jpg https://farm7.static.flickr.com/6066/6106981164_7cf0cf8bba.jpg

Ignore the RM stickers. They're only on there due to not being able to find original TS200R graphics..

Section59 · Spanner Monkey Joined: 05 Apr 2005 Karma :

Lots of interest i see! Laughing

Anyway, seeing as i've got the camera out and the motor is sat next to me, might aswell update on the engine front.

Cylinder head and barrel off :

Bore looks good to me, no scoring, can still see hone marks.
https://farm7.static.flickr.com/6067/6106587815_4484c949dd.jpg

Head is pitted quite a bit though, no signs of an explosion in there as the pits are uniform, whats the best way to clean it up, or will it be alright to use as is?

https://farm7.static.flickr.com/6065/6106587393_fd57fb183d.jpg

Need to take the clutch cover off to replace the plates/springs as when it was together there was serious clutch slip but i've hit a snag, mullered clutch cover bolt. Whats the best way to get this out, bearing in mind i don't have many tools at my disposal..

https://farm7.static.flickr.com/6183/6107135754_f4bb867a3d.jpg

at106 · Brolly Dolly Joined: 16 Jul 2011 Karma :

Good luck with your project Thumbs Up

To remove the rounded bolt, first try filing two flats on either side and use a good fitting open ended spanner on the two flats. If that doesnt work cut a slot accross the centre of the bolt head and use a good flat screwdriver to get it out. To cut the slot a junior hacksaw may fit if not you will need something like a dremmel.

stevo as b4 · World Chat Champion Joined: 17 Jul 2003 Karma :

Hi mate nice project! I'll be watching this progress with interest, as it's my kind of bike TBH!

Did you do the supermoto conversion yourself on it, or buy it like that to start with? I've never seen a TS200R motard before, and i reckon it will be a really cool and great fun bike to ride too!

We all have an interest in certain types and styles of bike that we like to seek out and specialise in, and Big bore 200cc versions of the popular 2stroke 125 trail bikes are one of mine! Id quite like to get a 200cc version of every Japanese 125 trail bike one day, and the Gilera and Aprilia 200cc models too.

chris-red · Have you considered a TDM? Joined: 21 Sep 2005 Karma :

You don't have to get the stem pressed out or the bearings changed to powder coat the yokes you will have to change the bearings to powder coat the frame. Thumbs Up

____________________
Well, you know what they say. If you want to save the world, you have to push a few old ladies down the stairs.
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WANTED:- Fujinon (Fuji) M42 (Screw on) lenses, let me know if you have anything.

Section59 · Spanner Monkey Joined: 05 Apr 2005 Karma :

dangerousdave · Traffic Copper Joined: 22 Apr 2011 Karma :

great project mate, will keep my eye on it & help out if i can.
____________________
1988 Kawasaki KMX 200

Previous: Yamaha YZF1000, ZZR600, KMX200, DT50, KX80, CG125, PF50

stevo as b4 · World Chat Champion Joined: 17 Jul 2003 Karma :

The Suzuki TSR is quite a rare bike even in 125cc form, as few were sold in the uk, compared to DTR's/KMX's and even KDX's are much more common than the TSR.

I don't think that Mainland Europe got the TS200R, and it seems to be one of the less imported Japanese 2stroke trail bikes too. There was an RG200Fun/Wolf, and i seem to remember seeing a broucher on line for one, that claimed 35bhp@9000rpm for the motor.

For spares, you can try the grey bike specialists and any trailbike specialists etc, but your probably going to get 200cc specific parts and engine bit's from Japan, or Aus/NZ much more easily. I dare say that some cycle parts, and bodywork will interchange with the 125's, but expect the suspension front and rear to be slightly different, as most 200cc versions of 125 trial bikes, had a better and different chassis spec than the 125's.

Examples would be the Alloy swing arms on the KMX and MTX200, and the dual radiator set up on the DT200R, along with better shocks and USD or stronger and bigger forks.

Werny · Traffic Copper Joined: 02 Feb 2011 Karma :

Good luck with the project!

Have you got that butchered bolt out yet? If the suggestions already given don't work, you can try locking a pair of molegrips onto it to try and undo it, assuming you have any, but it doesn't really look like you got the room there.

If you have a centerpunch, drill and a 6.5mm drillbit (assuming it's an M6 bolt), you could also pop a center dot in the middle of the head then drill into the bolt with the 6.5mm drill, when it drills through the head the remains of the head will just pop off the shank of the bolt, leaving you able to slide the casing off the protruding stud, then remove it at your convenience once the casing is out of the way.

Section59 · Spanner Monkey Joined: 05 Apr 2005 Karma :

Cheers for the tips and comments guys!

Nothing new done since last post, still havent got the bolt out, taking it to a mates garage tomorrow as he's got more tools than i have, should have it out in no time.

On the plus side, i've ordered new piston + rings, cost me £67 inc delivery from germany, but thats a damn sight better than the £150 redcar wanted!

Need to source a gasket kit, wrist pin and some circlips now, oh, and get some fork oil..

Section59 · Spanner Monkey Joined: 05 Apr 2005 Karma :

Well, now im fucked off.

Bought some new fork seals (pyramid parts...) about a week or so ago and fitted them. Got my fork oil in the post this morning so i figured i'd put the oil in and get the suspension part buttoned up and done. Guess what? They're fucking leaking. Rolling Eyes

I knew this would happen as after i bought them, i did some googling and i'm not the first. My fault for not checking first i suppose, still asking for a refund though.

So, waste of £7 there already, now i've got to find some decent replacements. Oh, i also lost a shit load of my new fork oil while re-stripping the forks down coz i got a bit angry and knocked the fork over, doh..

Also missed the postman while doing the above, so have to wait until monday now so i can go pick up my speedo cable and clutch springs.

I wish i'd stayed in bed... Mad

Although, i did manage to get that mullered bolt out, borrowed a dremel and cut a slot in it. Smile

Section59 · Spanner Monkey Joined: 05 Apr 2005 Karma :

Well, some progress finally.

Got my refund from p-k-n on ebay for the seals, after having the cheek to ask me if i'd put em in the wrong way! Rolling Eyes

So i sent em this pic to show how shite they were. Mr. Green

https://farm7.static.flickr.com/6068/6144210362_11a58c9da2_z.jpg

Got my NOS piston/rings in from the Netherlands and also bought a new wrist pin and little end bearing.

https://farm7.static.flickr.com/6083/6149855037_df1f66ccfb.jpg

Dry fitted it all together for now until i can get myself a gasket kit.
Am i right in thinking most of the gaskets from a TS125R will fit, besides base and head gasket? They look very similar...

Also got my new clutch springs and speedo cable through from wemoto (Excellent service. Will use again.) so those are all fitted. no pics sorry, although im sure you know what they both look like..

Removed front and rear wheel bearings, one of the back ones was a bitch and i ended up knocking the centre out then struggling for 15 min trying to remove the remaining outer ring.

https://farm7.static.flickr.com/6090/6149850563_b0e56ceac2.jpg https://farm7.static.flickr.com/6194/6150402466_2fc935d801.jpg

New bearings ordered and will be fitted asap once they arrive. These needed to be done anyway as i got an advisory for em at last mot.

Really want to get the wheels and hubs powdercoated as they look a bit manky but i dont have the cash for that at the min so going to leave them as is. Might do em after i've got it all back together and on the road.

Sooo, thats about it for now. Next update im hoping to have a nice swingarm and frame to show off, if i can afford it.

dangerousdave · Traffic Copper Joined: 22 Apr 2011 Karma :