THE BIGWHEEL THREAD!!! Yamaha BW350, BW200

haha.

Mr.Big Wheel , Cliff h , and Deaver , you guy's ever get together I hope somebody has there GoPro's running . It sound's like you guy's are makeing a Frankinsteinberg bike way up there in the northland . Keep it up ! We're all takeing notes and learning from this forum .

well, I got the bikes stripped down, fought the overly-complicated wiring on the donor bike down to just the essentials, and got to the first test fit.

the engine is just a little too long to slide right in.

not un-doable, but more work than I thought initially.

-Owen

Break out the grinder, you'll have that engine fitting in no time.

well, I want to try and do this without modifying the bike too much.

and unfortunately my welder just quit, so some care will have to be taken with what is cut.

anyway time for some pics!

the frame, unencumbered of anything to make it go:



the old, dead, motor:



the new motor, in all its glory!



the mess of wiring removed from the donor to get rid of all the non-essential functions:



and finally, the carcass of the KLR:



work will resume tomorrow, I am hoping to have the darn thing running by saturday morning so I can take it down to Homer and go tear up the beach!

also, the tank fell and broke, the whole top came off.

luckily the donor bike has a tank I can use(its metal, so no cracking issues) but it will be really ugly.
hoping I can find a more elegant looking tank to slam on it (the donor tank is off an XT650)

-Owen

No, I don't belive that the IMS pegs are any wider than the stock TW 200 pegs, just made from a more exotic material, read: More expensive. I am not sure how much stock TW 200 pegs are, but would be interested to know.

I'm happy to say 60bucks for stock vs 79 for IMS. Are u sure the 2x3" ims are the same as the stock pegs?

well, I got the new motor to fit into the frame!







very minimal cutting, just the hoop that the skidplate hooks to and the lower engine mounting tabs.
the rest of the "fitting" was accomplished by spreading the frame just a little with a highlift jack.

now the new motor sits nicely in the frame.
this will change the head angle a little, but only a few degrees (I only spread the frame about an inch) and if that ends up being a big deal I can always put longer shocks in the rear end.
although since I have a larger tire in the back, this may bring me back to stock head angle(or close anyway)

now I just need to finalize the mounts and put it back together.

-Owen

Nice post, keep up the good work!

Did a little research on the tw forum and the stockers by all accounts seem to be the usual standard. in fact the tw crowd use IMS footpegs too. Some guys like these cheaper alternative (chinese) are these the footpegs u "trialed"

www.ebay.com/itm/Steel-Foot-Pegs-Yamaha-PW-50-PW-80-TW-200-/350583609088?pt=UK_Motorcycle_Parts&hash=item51a0695700

No, I am not sure. I was looking for a higher quality set of pegs after my cheap made in China ones failed, so I was willing to look at a more quality set of pegs price be damned seeing how important it is to not have your pegs fail on you/me.

hit my previous post link, are these the chinese one u had? they are like ims and of course larger than the stockers. again the tw forum seems to be happy with both with no complaints of failure.

Owen: are u gonna give that frame and engine a spray or 2 of paint? I would once u get it all figured. Since u got it all apart, i'd be nice.

Deaver, yes my failed pegs were cheap, made in China pegs made from aluminum. They were made for a TW 200, but I put them on my BW 350 in order to have the larger size that the TW pegs have. If they were made of steel, they might have lasted more than 1-2 rides.

http://www.ebay.com/itm/Steel-Foot-...88?pt=UK_Motorcycle_Parts&hash=item51a0695700

these are steel and by all accounts on tw200 forum they are IMS without the tag. i just ordered and will update upon installation.

yeah, I will paint all the new mounts and stuff.
the frame still has the factory paint on it in really good condition, and anything I do on my back porch wont be nearly as good as that, so I will leave the frame itself alone.

just started a new job, on top of college, so progress may slow a bit (I no longer have 8 hours in the middle of the day free) but I am going to try and have the mounts finished tomorrow night so I can re-assemble it on friday and take it to homer for a test ride.

I got the rear motor mounts built, and the front one mocked up yesterday.
should be pretty quick work to finish up..

-Owen

looks like a exciting build!

That's going to be AWESOME!!!

If you have that done by Friday then you will have completed a non-stock engine swap in less time than it takes me to change a fork seal.

We'll have to go run that out to the Knik Glacier when it's done and properly baptize it.

Regards,

Mr. BigWheel

By immersion, right?

Might be a bit late here, but the ATC 250R was air cooled 1981-1984, the 1985-1986 models were pumpers.

I'm a massive 3 wheeler nut, same with big wheels, this thread has my attention