Motor apart

I never thought I’d do it, but with a mate’s help (thanks Jai) we managed to free the barrels from the pistons and case. However, we also damaged both pistons (busting some of the skirts off them) and also one barrel. Check out the photo’s.

Some observations. The clutch is in mint, with plenty of life. Actually that whole side of the motor is in great condition. Inside the crank-case is full of mud. I’ve yet to split and open it up.

Overall, I can now get back in to the swing of things with pulling down and cleaning up this bike.

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Engine tear down

Someone on “Perth Street Bikes” recommended that I stop everything and focus on freeing the barrels from the motor. If I can’t get the barrels and pistons out, then there may not be any point going further.

Yesterday I had the engine out, finally, today took the carbs off, reed blocks, and started to clean some muck out of the inlet ports. YUCK. I’ve propped the motor up so the barrels are just about vertical, and poured some diesel in to let the thing soak a while. What a mess. I’m quite worried that I won’t be able to free the barrels from the pistons.

The crap in the intake is sort of mushy, like grease, but, well, not grease obviously. As soon as I pulled the heads, one of the barrels had oil on top of the piston, interesting. The other completely dry. The heads came off easily, as did the spark plugs, the eight screws holding the reed blocks in a little tough, one was very tough, thanks to my neighbour who had an appropriate tool to remove the tough screw as my big screwdriver wasn’t happening.

Interestingly, my Yamaha workshop manual instructed me to undo the oil-feed banjo fitting from each barrel. My motor doesn’t have such fittings, it has a screw covering each hole, and they look like ‘factory’ type screws too. Did not all models have the oil pump feed to the intake ports of the barrels? hrmmm

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tough gets tougher

I’ve spent a couple of days soaking some screws and bits in WD40 to try free them up. Mainly the wiring loom terminals off the stator, and the screws holding the oil pump cover on the casing (tough)!

Today I managed to get them all undone, I removed the loom, undid the throttle cable off the oil pump, and undid the cables from the carbs, only to find yet another mess!

As the pics show, oil pump area corroded a little, left carb really corroded, throttle cable just broke off. *groan*

It seems the entire left side of the engine is corroded from water damage, carb, stator, air box, exhaust port, piston. It’s going to be an absolute mess inside.

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Tear down

I’ve started the tear down, removed the silencers, headers, seat, fuel tank, oil tank, battery box, chain guard, chain, clutch lever, and the clutch-lever side engine cover (disaster, see pic).

Check out the photo’s. It’s too hard to tell if the silencers are recoverable from the rust, a pro will need to take a look. The battery box is fairly well rusted and needs repair or replacing, the air filter housings are also quite rusted. The engine-side sprocket is missing teeth and wrecked.

It looks like water and god knows what else has been in one cylinder judging from the mess inside the exhaust port. It’s like the headers were slightly loose, not properly mated to the engine, therefore the gap has let the weather inside.

I am wondering if the engine covers are supposed to be sealed at all with some kind of sealer, around the magneto/gen area. As you can see from the pics, water has gotten in and had a field day with basically everything, it’s a total mess. Best way to clean this? Advice is welcome!

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It starts here

Yesterday my father-in-law and some mates moved the bike from Dads place to mine. It went off without a problem, quite easy really, we had more muscle than we needed.

Got it home, rolled it off the ute on to some cardboard in the garage, and prepped my work area.

I’ve pulled a few bits off, tank, seat, chain guard and pipes. Will probably pull the motor and “muddy’s” next, then all the rest, down to bare frame.

Still lots of seized and rusted screws/bolts to soak in WD40 before I attempt to remove!

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Rescuing the RD200

Today I went back to dad’s to try and pull the RD200 out from under the tarp. It wouldn’t move without picking it up and dragging it out.

Ended up dumping two can’s of WD40 on to it to help free it up a little and managed to get the rear wheel turning with the bike in neutral (chain free’d up).

Initial inspection tells me:

forks badly rusted (stanchions)
spokes quite badly rusted
silcencers possibly beyond re-chroming
kick start lever missing
one rubber fuel tank guide/bush missing
front left indicator lens broken/gone
all indicator lenses very worn
clocks in great condition but dial faces showing signs of weathering
key fits ignition, doesn’t work (is correct number). Fuel tank has no key (different number) and is locked
Owner previous to dad home-painted the bike, red on panels/frame, and black on other parts like mirrors, switch casings, levers, etc. It’s actually helped preserve the bike

Frame and engine numbers are matching and start with “585″. Compliance plate says it’s a 1975 bike. Original colour (from what I can tell) is blue.

Dad’s other RD200 (the wreck), has matching numbers prefixed by “1J1″, and plate says it’s a ’77′ bike. It has a front disc brake and the “coffin” fuel tank, many parts are plastic instead of metal too (airbox, oil tank, etc)

Enjoy some photos:

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Welcome and background

Hey all, if you are reading this, then I guess you are interested in Yamaha RD200′s, or perhaps vintage Japanese two-stroke bikes. Welcome!

The story goes something like this (I will try to keep it short). I was visiting dad one day (last week) when we started chatting bikes, and I asked him if he still had his Yamaha bike, thinking that there was only one. Well, he has two, one which he crashed, and one which he didn’t.

Turn’s out, the bike sitting out the back, in the weather, for 30 years under a tarp, is complete. “What bike is it” I ask. “A 70′s Yamaha RD200″ he says. Hrmm. A quick google on my iPhone tells me the bike is fairly rare these days. He goes on to talk about the days he was riding before he had a nasty crash (on the other wreck, also in the back yard, also an RD200, more on this later).

Dad bought this bike off a “young fella” for about $180. Hang on dad… a young fella? C’mon, you were maybe 24 yrs old yourself back then! Dad rode the bike for a very short time until one day it wouldn’t start, he just let it sit. Well actually, dad had a nasty bike crash that pretty much ended with dad never riding again. The RD (not the wrecked one) sat and sat, and seized up.

It’s been sitting under a couple of tarps, in the open, out the back, in the weather, for 30′ish years, un-touched. I had to take a look

Stay tuned for my next post (with pics) of the uncovering.

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