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  #31  
Old 30-04-2018
metaltriumph metaltriumph is offline
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Join Date: Aug 2012
Posts: 60
I still need to get a new piston - but in the meantime the cylinder got scrubbed and degreased and the clutch cover got scrubbed and painted with VHT aluminium

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  #32  
Old 07-05-2018
metaltriumph metaltriumph is offline
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Join Date: Aug 2012
Posts: 60
still waiting on the piston but thought i would do a mockup.

still need to
- clean up the badly carboned power valve parts
- fit front and rear brakes
- clean and restore radiators
- buy a battery and headlight
- clean up plastics
- install indicators and lights
- clean up wiring loom
- rig up a speedo and ignition switch
- etc etc etc

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  #33  
Old 07-10-2018
metaltriumph metaltriumph is offline
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Join Date: Aug 2012
Posts: 60
So i have a +1 piston, rings, etc all ready to go. The cylinder has been rebored to suit.




However i noticed my power valve setup is a bit screwy. It appears like the centre valve of one of the sides has the wrong curve/shape...



it is not just simply a case of the PO swapping out the LHS for the RHS - as the outer radius is correct - its just the curve of the mouth that is backwards. Weird. It cant be that big of a deal, the bike was running previously. It is impossible to find these parts. I have a spare set but as you can guess, the required centre-valve with the floating pin is absolutely munched.





One side has a roll pin installed hard, the other seems to want one that floats? I have the "floating" roll pin here, ill have to work out how it is supposed to be seated in there without getting loose and killing the cyclinder.








Slow progress and finicky.

However, I also found a pretty good match with an 1993 RMX250 headlight

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  #34  
Old 19-10-2018
metaltriumph metaltriumph is offline
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Posts: 60
So a mate of mine tells me that the valve piece was likely flogged out and so needs to be completely filled with tig weld and then a new hole drilled. Seems OK to me.
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  #35  
Old 3 Weeks Ago
mitch199 mitch199 is offline
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Join Date: Dec 2016
Posts: 4
Hi mate. I had a TS200R, 93 model. Loved it back in the day! Only sold it to buy a YZ but wish I kept it around.
For Plastics, I ended up searching like crazy because I wanted an RM style rear fender.
IF you are savvy with ebay, you'll pick up a Spanish Market late 90s RMX50 rear mud guard that will fit, shaped like the RM style for the big subframe the TSR has.
Over there if the bike is under 50cc they can almost rego them for free hence the weird 50cc enduro bike market in Europe (full size bikes with 50cc engines). The same Side Covers fit, and the seat is the same too. Could make her look like a proper 90's RM, like I always wanted when I had one as a young bloke. If only the internet was around like it is now back then!
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  #36  
Old 3 Weeks Ago
mitch199 mitch199 is offline
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Join Date: Dec 2016
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Thats the RMX 50 in all its glory!



Not my TSR, but one very close. Notice the similarities. I reckon if you were mad keen, you could get the RMX Tank and Shrouds to work too, and make it look like a proper 93-95 RM250!
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  #37  
Old 3 Weeks Ago
mitch199 mitch199 is offline
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Join Date: Dec 2016
Posts: 4
https://www.bikepics.com/pictures/21...suzuki-tsr-200

Not mine but very similar to my 200.

I bought a KTM 200 EXC years later (2007 brand new) and was mainly due to loving the TS200R. Different bike of course, light years ahead, but the TSR was always a hoot on the trails.
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  #38  
Old 2 Weeks Ago
metaltriumph metaltriumph is offline
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Join Date: Aug 2012
Posts: 60
ok so hopefully the powervalve saga is over - I had a mate tigweld the munched-up hole then i re drilled the 5mm for the pin. Then i had to file the thing flat for what felt like forever. all fits in nicely now.





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  #39  
Old 2 Weeks Ago
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gasgasman280 gasgasman280 is offline
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Join Date: Aug 2009
Location: birdwood south oz
Posts: 1,395
I take my hat off to anyone who takes on a rebuild of a bike with a short model run and bugger all stock parts availability.

But nothing like zero parts availability to make or break you and discover whether you have a mini engineer in you 😜
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  #40  
Old 11 Hours Ago
metaltriumph metaltriumph is offline
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Power valves, cylinder and rings in and top end buttoned up




wasting time recreating lost parts....





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