First resto: 74' Yamaha RD200

[JamesM]

Where do I start, I don't even know if it's a '74 yet. I posted in the 2 stroke area, and the newb's area and received a warm welcome, thanks all. It was recommended that I start a "project" thread.

Story goes like this. Dad has this bike, it's been out the back under a tarp (in the weather) for 30 years, it's complete, but ceased up, and has some surface rust and corrosion, etc. It's basically a mess. Anyway, he said I could take it. Something for me to tinker with (since I gave up tinkering with cars years ago).

When I know more about it, I'll post more, but I hope to restore this thing.

I'll honestly say I don't know a hell of a lot about bikes, but I'm not afraid to get my hands dirty, I've built engines/gearboxes before. My daily ride is a two stroke Vespa, hehe

I'm hoping to post progress, and learn a thing or two. Very keen to learn from others here, especially those who have owned, do own, or have rebuilt one of these (or something similar). Be prepared for a million questions!

Planning to go pick it up next weekend, will get pics up at when I do! (maybe even some pics as-is, in the back yard, under the tarp? hahahaha *face palm*

Cheers, James

[brethren22]

welcome and good luck with the project James. i've got an RD400 project moving along very slowly on here. good to see another old smoker getting some love

let's see some pics!

[JamesM]

Will grab pics this weekend when I go pick the bike up. as is (under the tarps), moving it, getting it home, etc. You'll flip out when you see how rooted it is. haha

[SPman]

Bugger - I should have brought that RD200 project over from Brisbane, after all. This guy has some parts netbikes Motorcycle Auctions Motorcycles Classifieds Motorcycle Sales Cafe Racer classic vintage motorcycles

[JamesM]

Thanks mate, I sent the guy a text to see what he has left, pitty he started wrecking it, it looked 90% complete. For reference, the bike I have is in similar condition, judging by the pictures. Will get some pics of mine up this weekend, or sooner. Of course, once I have it in my garage and I'm pulling it down, the epic questions and updates will begin!

[JamesM]

Bugger - I should have brought that RD200 project over from Brisbane, after all. This guy has some parts netbikes Motorcycle Auctions Motorcycles Classifieds Motorcycle Sales Cafe Racer classic vintage motorcycles

I "txt" the guy, asking what he had left of the wreck, only has what is listed at this link, not too much that interests me, except maybe the muddy and the complete rear wheel. I'll take another look at the project before starting my parts search I think!

[JamesM]

well here it is guys, pics as promised.

I think I'm in a little over my head here?
RD200-77.jpg

[zebathin]

Hahaha, great condition!

[JamesM]

Hehehehe.

That is an RD200, but not the one I am restoring

This is the bike dad crashed. Turns out it's a 77'. Dad still has the 'coffin' tank and front muddy too

Pics of actual project will be up tonight!

[JamesM]

some pics, just before pulling it out, and after a quick cleanup. Compliance plate says it's a 1975, but the aircooledrd forum says the shape makes it a 73/74 (RD200A). The frame and engine num's match. Biggest problems that I can see from a visual inspection are the badly rusted forks, and the silencers.

Only thing missing (from what I can tell) on the entire bike, is the kick start lever.

Found the key for the bike too, but it doesn't do anything in the ignition, the numbers do match. No key for the tank, and the tank is locked

Dad and I emptied two cans of WD40 on to it, and eventually managed to free up the chain. Easily selected neutral, and was able to turn the rear wheel. Front wheel is still seized up, will give it another few day's of WD-soaking before I move it.

The bloke that owned it before dad has re-painted it red, and painted various other things at the same time (engine, levers, mirrors, etc), in a way, it's preserved the bike well! I'll get more photo's up on my site

beforepulled.jpg afterpulled.jpg

[brethren22]

better than the one in the first pic! it doesn't look so bad. seems like most of the important stuff is still in good shape. you can get your hands on new fork stanchions and pipes shouldn't be a major issue. are you looking to restore it to (close to) original condition?

[JamesM]

From what I've read, pipes are the hardest to acquire. when I get these ones off I'll take em to a pro to see if they can be restored and re-chromed. I plan to restore it to original condition (factory) if possible! I've put a heap more pics up on my site Yamaha RD200 | a full restoration of my fathers RD200

[JamesM]

wow, what a week. I've been at home most of the week with a nasty stomach bug, only just got to have another look at the bike today..

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!

go to my site, for the bigger versions:

[brethren22]

damn! i thought mine had seen some time in the rain but yours wins hands down. i think you'd do well to get yourself a new ignition set up but you might be able to salvage that with a lot of careful and determined work on the original

looks like that cog is toast too. no doubt the chain is well and truly gone so i guess you can put those on your list of part to buy. don't let the dirt put you off though. keep going, it'll only get better!

[JamesM]

I would say a bunch of components will be damaged beyond function in there. "a new ignition setup" easier said than done... from where exactly? hehehe

[brethren22]

RD200 could be tricky. all kits seem to list the 250 but not the 200. these are the ones you'd look at but i don't know whether any of them would be compatible or not. need to get some expert advice on someone who knows the 200 and 250 pretty intimately i would imagine

Powerdynamo for early aircooled Yamaha RD with lighting (small shaft)

HVCcycle - Newtronic Ignition

Yamaha RD250/350/400/R5/DS6/DS7 Parts:Ignitionoints / Condensors / Cams | Economy Cycle

[JamesM]

Hey pretty awesome kits. replace everything! coils, even the battery. crazy...

the RD250 and RD200 are very different actually

ultimately I'd like to keep it as original as possible. I need to pull it all down and look at the damage more closely, but ultimately an entirely new unit or good used replacement would be the go

[JamesM]

gee this is getting fun *groan*.

Today I managed to get the loom off the stator after soaking it big time in WD40, also managed to get the oil pump casing off and undo the throttle cable ready to pull the motor. I started to get the throttle out of the carbs only to find the left carb loaded with corrosion, and snapped the throttle cable as I undid the cap. RHS carb I've not yet fully undone, fearing it will also break, but a little look inside with a torch shows it's nothing like the LHS carb, not as wrecked. I just need that throttle cable out of the RHS carb and then I can pull the motor.

It's looking like water has gone through the entire LHS of this motor (carb, head/block/piston, stator). It's a mess.

some thumbs below, head to Yamaha RD200 restoration blog for bigger pics:

[D.J]

probably need to start with a new loom for the ignition considering the weathering, one of the ACRD guys makes them. All the condensors and points are available new and you can bead blast the stator just make sure you protect the inside, you will also need a special bolt to get the rotor off. Before you go much futher make sure you are able to pull both barrells of without any damage to the cases. I have had a 250A with a piston so badly siezed that the crank, barrell and top case was a writeoff. Exhausts look too far gone to rechrome because of the damage that they do when they pull the old chrome off (check out my RD250E thread for an example with the rear guard),
Pipes need to be cleaned with caustic before the chromers will touch them as they don't want oil and crap in the soloutions (there is the burn out method).

[Twigs]

This build looks really interesting. I'm sure your dad will love to see it re-done up
Best of luck mate! Always ask for a helping hand if you need it- PSB is filled with lots of people who know ALLOT about bikes and resto's.
I'll keep a close eye on your blog- looks really good