Author Topic: WR200 UK (Easy?) build project  (Read 1942 times)

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Offline wishiwas16again

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WR200 UK (Easy?) build project
« on: July 29, 2018, 06:47:19 PM »
Hi All,
I'm glad to have found an active group of WR200 owners and enthusiasts  :)
I had one of these new in 1998, loved it, and have regretted selling it ever since.  But in the interests of nostalgia and pretending to be young again, I've just bought this bike. 
It looks a bit neglected and unloved, but basically appears to be complete, and hopefully a great starting point for an easy-ish rebuild.
I've not put a screwdriver or spanner on it yet, so who knows what will be revealed as I get stuck in.
As far as I know, these were mostly unchanged apart from colour schemes over the model life.  I'm not certain on the age of this bike, but the blue frame puts it 1995 onwards I think.
I'll post my progress and no doubt appeals for help along the way?

Offline Spannerz

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Re: WR200 UK (Easy?) build project
« Reply #1 on: July 29, 2018, 07:06:08 PM »
Yay!  This all looks very familiar! Rebuild costs should be very reasonable.  eBay is your friend.
YFS200 Blaster
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XL200RD Honda
WR300 Husqvarna

Offline Martin I Henry

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Re: WR200 UK (Easy?) build project
« Reply #2 on: July 29, 2018, 08:34:36 PM »

Welcome to the forum wishiwas16again.

That looks like a great project.

Should keep you busy for a while !

Cheers,

Dave R.

Offline wishiwas16again

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Re: WR200 UK (Easy?) build project
« Reply #3 on: August 06, 2018, 07:08:20 AM »
Like most, I'm pretty busy so projects like this have to fit in where they can. 
I've made a start and I'm wondering if this bike has ever been cleaned?!
I now know what a 'barn find' is...  Seems something has been living in the airbox!

Offline Spannerz

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Re: WR200 UK (Easy?) build project
« Reply #4 on: August 07, 2018, 08:49:21 AM »
It's a good sign you have blue fluid in the resiviour.  This is something I (most people?) look for when buying a motor.  Lack of treatment in the coolant can easily be a write off... Unless it's soap? Lol.


Also better check your Powerbands.  Might have a few nuts loose...
YFS200 Blaster
WR200 Yamaha
XL200RD Honda
WR300 Husqvarna

Offline wishiwas16again

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Re: WR200 UK (Easy?) build project
« Reply #5 on: August 18, 2018, 02:22:03 AM »
Next step, a serious clean - it already looks much better!  The plastics came up pretty good and I got most of the oily grime off the rest of it.
Sounds like it might need a little end bearing?  Hopefully nothing more serious.
If I did this right you should see and hear it here... http://youtu.be/m90EN0LnkLQ  you might have to copy/paste the link.

Offline wishiwas16again

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Re: WR200 UK (Easy?) build project
« Reply #6 on: August 18, 2018, 02:38:15 AM »
Other observations:
Rear shock bump stop has disintegrated, so the shock will need to come apart.
Both shock ends have loads of play so I'll get bearings for the whole linkage and swingarm and do it in one go.
Fork chrome is good and they don't appear to be leaking.  But the outer tubes are tarnished and I'm not sure how to get them clean again.
Wheel rims are tarnished but should clean up ok, and the spokes don't seem to be corroded so that's a bonus.
Frame is about the worst part, so I think it will be simpler and by far the best result to get it powder coated.
Does anyone happen to know the RAL number for the 95 onwards blue frame colour?

Plans under way:
Ordered a few bits...
Seat cover
Air filter
Found new old stock front and rear brake discs (not sure it really needs them), wheel bearings front and rear and a set of foot pegs.

So I can get it registered eventually and trying to keep it original I found some XT handlebar switches which should give me Hi/Lo beam and horn.
For a speedo I've got a WR125 digital unit and drive coming - the WR125 has the same front axle p/n as the 200 so I'm hoping this is going to a neat solution with minimum (read none) engineering.  We will see  ::)

Offline wayne61

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Re: WR200 UK (Easy?) build project
« Reply #7 on: August 21, 2018, 07:18:09 AM »
I'd go no lights.
You gonna be riding it in the dark?
Go soothingly on the grease mud, as there lurks the skid demon.

GRIP AND RIP CRAIG AND CHRISSO!!!

Offline wishiwas16again

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Re: WR200 UK (Easy?) build project
« Reply #8 on: August 25, 2018, 05:12:58 AM »
Everything is off the frame apart from the linkage - it won't budge and access is awkward  >:(
I guess I'll have to get some heat on it.

Offline Spannerz

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Re: WR200 UK (Easy?) build project
« Reply #9 on: August 25, 2018, 07:05:53 PM »
This is the same bolt problem I have.  Mine has the wrong bolt in there and I guess it was also stuck and then cut out.  I would much appreciate it if you could take a photo of what's left when you finally get it out.   Yours actually looks bent.
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Offline wishiwas16again

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Re: WR200 UK (Easy?) build project
« Reply #10 on: August 27, 2018, 03:38:59 AM »
Had to cut the bolt out in the end - the problem is that you can't hold the collar still while attempting to rotate the bolt  >:(  I was also nervous about using a lot of heat on/near the alloy linkage.
It's a PITA, but it's possible to get a cutting disc between the frame and the linkage - you need to cut it on both sides. 
I used a flywheel puller to press on the end of the bolt as it was obviously moving around once I'd cut one side off. 
I also used a dremel to grind the weld that stops the head rotating, this allowed me to turn the bolt every so often while cutting.
Looking at pictures and parts diagram it seems the early bikes had grease nipples on the linkage bolts and swingarm, they disappeared around 1995.  Whether these help to prevent this problem I don't know, but they seem a good idea.  Either way, it would be a good idea to take this bolt out and grease it one in a while to avoid a repeat.

Offline wishiwas16again

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Re: WR200 UK (Easy?) build project
« Reply #11 on: August 27, 2018, 03:44:19 AM »
Couldn't include all the images in one post - here's a version with grease nipples, there are two versions of this I've found, each using a different bolt with the nipple at opposite ends.
Seems none of the parts are available any longer.


Offline wishiwas16again

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Re: WR200 UK (Easy?) build project
« Reply #12 on: September 15, 2018, 03:10:43 AM »
A bit of work needed on the frame - small crack on one the joints, but easily fixed.  Side stand and frame built up a bit with some weld and re-ground to get rid of some of the excess free play.  Frame, stand and spring all ready for powder coating.

Offline wishiwas16again

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Re: WR200 UK (Easy?) build project
« Reply #13 on: September 23, 2018, 04:12:01 AM »
Back from the powder coat shop  :)

Offline wishiwas16again

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Re: WR200 UK (Easy?) build project
« Reply #14 on: September 23, 2018, 04:15:45 AM »
And a growing collection of new old stock...

Offline wishiwas16again

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Re: WR200 UK (Easy?) build project
« Reply #15 on: February 03, 2019, 12:50:15 AM »
It's been a while...
Rear shock now fully rebuilt plus new bump stop and powder coated spring.  Just sorting out top bearing now.
Forks also rebuilt with new seals and bushings.

Offline Devondan

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Re: WR200 UK (Easy?) build project
« Reply #16 on: February 03, 2019, 05:08:44 AM »
Looks good!
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Offline killindini1

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Re: WR200 UK (Easy?) build project
« Reply #17 on: February 03, 2019, 08:34:26 AM »
Looking Good,
Did you Alodine the shock body and fork lowers?

Cheers,
Steve.
Beer is more than just a breakfast drink

Offline Cooky375

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Re: WR200 UK (Easy?) build project
« Reply #18 on: February 03, 2019, 01:38:11 PM »
That looks like a great job on the Alodine, nice and even finish. That would of taken a lot of prep work.

Offline wishiwas16again

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Re: WR200 UK (Easy?) build project
« Reply #19 on: February 03, 2019, 08:23:04 PM »
If only I could take credit for the Alodine... but all I did was clean.
I certainly spent some time on it, first de-greaser and then hot soapy water. I think the bike had stood caked in dirt for some years before I got it, and there is some sort of yellow tint to a lot of the alloy parts. I wonder if it's stained from the mud it was covered in.
Thanks for the encouraging words - if I can get everything else close to this it should look pretty good when finished  :)

Offline wishiwas16again

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Re: WR200 UK (Easy?) build project
« Reply #20 on: February 03, 2019, 08:39:13 PM »
I did a bit of research on the age of the bike.
I found date marks on the bottom of the tank, the wiring loom label and the rims.  They are all the marked late 1997.
This link http://files.semestergas.se/Yamaha_Model_index_-_1958_-_2008.pdf (found somewhere in the depths of the forum :) ) lists frame numbers vs. year.
Nothing for 1997, but my number is close to the start point for 1998, so everything adds up to being a 1996 model, manufactured late 1997.


Offline wishiwas16again

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Re: WR200 UK (Easy?) build project
« Reply #21 on: April 09, 2019, 02:19:32 AM »
Here's everything that came out of the swing arm...

Offline wishiwas16again

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Re: WR200 UK (Easy?) build project
« Reply #22 on: April 09, 2019, 02:21:23 AM »
And here's a cleaned up linkage :) with all the tired and rusty bits that came out...

Offline Spannerz

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Re: WR200 UK (Easy?) build project
« Reply #23 on: April 13, 2019, 06:11:51 PM »
If you are in desperate need, I kept some/all of the old parts that came out of mine when I did it, I can give you. I also blue printed the pins and posted them up in my swing arm thread. 
YFS200 Blaster
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XL200RD Honda
WR300 Husqvarna

Offline wishiwas16again

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Re: WR200 UK (Easy?) build project
« Reply #24 on: April 14, 2019, 04:04:48 AM »
Thanks for your offer of help Spannerz - appreciated  :)
I think I have all the bits needed for the linkage and swing arm now in 'all balls' kits.  I saw your post with the drawings for the pivot bolts etc.  I hope I can avoid manufacturing, but great to have the dimensions of them if it comes to it.  The one that fixes the link to the frame seems to be the one that really wants converting to have the grease nipple like the early bikes - cheers.

Offline Fixitandy

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Re: WR200 UK (Easy?) build project
« Reply #25 on: April 14, 2019, 10:17:24 AM »
Hey, excellent job so far man, pardon my ignorance, but what is Alodine? What does it do? & where do I get it? Cheers Andy.

Offline wishiwas16again

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Re: WR200 UK (Easy?) build project
« Reply #26 on: April 15, 2019, 02:59:23 AM »
Thanks for the encouragement Fixitandy  :)
I'm sure google can tell you more accurately, but as I understand it Alodine is a coating that can be applied to metals to prevent/resist surface corrosion.  It looks yellow/gold coloured.  I'm not sure that it's something you'd easily be able to do at home.

Offline Cooky375

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Re: WR200 UK (Easy?) build project
« Reply #27 on: April 15, 2019, 11:54:42 AM »
Alodine is pretty simple to do. Mix the powder with water and immerse the part for the time you want. The longer you leave it the darker it gets. The hard part is getting your surface to an even finish other wise blemish's and scratches are very noticeable. I've only had a small play with it, but it seems simple enough.

Offline wishiwas16again

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Re: WR200 UK (Easy?) build project
« Reply #28 on: April 16, 2019, 08:03:50 AM »
Latest challenge - wheels.  The rear rim is shot  :( The alloy is de-laminating and flaking apart. There's also a flat spot/bulge.  Hub looks ok and the exposed parts of the spokes are not rusty, but I'm not sure spokes will be salvageable as there is a lot of rust on the inside of the nipples.  I've put penetrating oil on them and I'll see if they will budge in the next day or two.

Anyone got any tips on getting corroded spokes undone?  Or has anyone got spare wheels/rims??

Front wheel is not corroded to the same extent, but if I have to replace one rim then maybe I'll do both, else it will look like the poor relation.
Picture of the Rear Rim...

Offline Cooky375

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Re: WR200 UK (Easy?) build project
« Reply #29 on: April 16, 2019, 02:29:27 PM »
That looks pretty good and salvageable.

Only because I didn?t want to put the money into rims until I had the rest of the bike sorted on my IT200. I took a couple of weeks to work all my nipples free. With the rim standing up right I?d spray penetrant into the nipples on the top of the rim and then on the spoke nipple junction on the bottom half of the rim. I?d rotate the rim a quarter a turn after a day and repeat. I?d try the spoke spanner occasionally and for the last stubborn ones I used some heat. Maybe if I used heat straight away it wouldn?t have taken so long.

Offline fred99999au

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Re: WR200 UK (Easy?) build project
« Reply #30 on: April 16, 2019, 08:24:22 PM »
agreed. Unless the buckle is really bad, Ie run rims worse than that. Go at it with a rotary wire brush.

Offline Spannerz

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Re: WR200 UK (Easy?) build project
« Reply #31 on: April 17, 2019, 09:52:12 AM »

Anyone got any tips on getting corroded spokes undone?  Or has anyone got spare wheels/rims??

Front wheel is not corroded to the same extent, but if I have to replace one rim then maybe I'll do both, else it will look like the poor relation.
Picture of the Rear Rim...

I have started my front rim, which looks exactly the same as your rear rim.   I took it to a specialist to get re-trued, he took one look at it and told me it was f**ed.   My nipples look exactly like yours and he puts on heat, portable blowtorch, trys to crack them with a spoke wrench, from the spoke side.  New spokes were about $2 each x 36 + labour, + new rim, suddenly I have a $300 front wheel which might as well get a new tube and tyre.   

The thing that wrecked my front rim, I do believe was loose spokes, so you'll be wise to get that sorted unfortuneately.

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XL200RD Honda
WR300 Husqvarna

Offline Cooky375

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Re: WR200 UK (Easy?) build project
« Reply #32 on: April 17, 2019, 02:57:49 PM »


http://www.yamahait.com.au/forum/index.php/topic,24320.80.html

http://www.yamahait.com.au/forum/index.php/topic,24263.0.html

For me I work off a budget and try to get the most out of what I can use before buying new. I rather buy fuel and ride time than new parts.

My 200 has coped some abuse over really rocky terrain and my rims are holding up. However I know they wont last for ever and will keep an eye on them.

My 175 cracked from the abuse in rocky terrain but I kept on using it. The crack grew another inch from the photo in the link above before I replaced it.

If I was hitting triples or racing Finke, no doubt I would replace immediately but for trail hacks(I'm not saying you are one, I am), you will be surprised how far mechanical items can be pushed. You just have to be realistic with the finances and your risk assessments when riding with old bikes.