Tallpaulself

Yeah, got them in there and the casing pinch bolts tightened down. Just looks so wrong to have that gap. Thanks for the reply!

Hi all. I've seen it documented that later models have a gap between the left swing arm and the frame. Is this the same for older models? My 2002 txt 200 has roughly a 5mm gap

Evening all. The rebuild continues on my dad's 2002 txt 200. I got it with bits all over the place and am now wondering on the correct locations for stuff like CDI, voltage regulator, coil pack etc. The space between fan, bottom of tank and spark plug is pretty tight so seems it all needs to go in a certain way. Anyone have photos of their set up? Ta!

Thanks all for your replies. I eventually found a used top hat from an identical casing. Turns out the info on the earlier clutches having a smaller diameter top hat was guff and it's the other way round. Cost a week of thinking I was going mad 🤔

I ended up getting a used part. The piston I got what from the same casing and was smaller internal diameter. So somewhere along the line a supplier has got their facts confused as later year casings ('03 on) are a smaller i.d, not bigger as I was originally told

Something I contemplated, going for maybe a 2mm thick o'ring. But I decided against it as I didn't want the piston applying uneven pressure on the clutch spring fingers. Think it needs to be a snug fit to stop it wobbling. When 'fitted' there's maybe 5mm play at the base where the roller bearing sits

So here goes. I'm doing up my dad's 2002 txt pro 200 or edition 200, whatever it's actually called. The clutch casing on it has threaded at the banjo bolt so he bought a replacement casing. Trouble is none of the internal bits transfer over. I know about the 2003 onwards upgrade to it and thought that by getting a 2003 on clutch piston, spring and spring helper the problem would be solved (thinking that the casing was newer anyway). But no! The piston flaps about on the spigot in the casing. Internal diameter of the piston is 14.98mm which I'm told is the newer upgraded clutch one, and that the 2002 item was narrower. Yet the return spring and helper fit perfectly in the spigot (see pics). If the piston is the right size yet too loose you'd think the casing is wrong, but then why do the spring and helper fit so well?! Also the new clutch casing has a part number that gas gas parts finder doesn't recognise. It's frying my head! Any thoughts?

I don't suppose any clever, organised person out there has a list of bearing sizes for techno swing arm and dog bone? Need the swing arm bearings, dog bone bearings and the rocker link bearings. The user manual usefully lists all engine bearing sizes but doesn't for suspension parts 😐

Answering my own question here. Apparently back plate is '99 techno and rev models. Anything before that didn't have the castings or threads for the back plate so it's fixed. It also coincides with the 99 onwards having an upgraded CDI etc. So it's not timing as timing is fixed on these. Well...not manually adjustable anyway. Always learning...

Me again... Needing some confirmation on techno stator setup. Im running the Ducati type ignition and my stator is mounted directly to the engine with no backplate or way of adjusting timing. Should this have a backplate? There's lots of photos of replacement items that all have a back plate with them. Im currently eliminating why the damned bike will not start and backfires. Carb is cleaned with new jets, plug is correct with correct gap and good spark. Inlet is clean and not leaking. Exhaust flows well. Replaced matched piston and barrel along with head orings and base gasket. Starting to scratch my head now and thinking timing or possibly faulty cdi? I've attached a photo of what's to be found online and also the set up on mine (with stator removed)

I may try that down the line Dave. Meantime I've got another matched barrel and piston coming. If I can fix it, will be worth having as a spare because the barrel is spotless besides this pain in the ass 🤣

I see a 'b' on the piston

Glad you posted this! Any way of identifying?

Does anyone have a fairly decent barrel only for sale? Plenty barrel/pistons for sale, but piston is fine. Just a barrel needed. See the photos to see the cause of a lot of swearing in the shed 🙈🤣

No, someone else must have nabbed that one off you! This is another non runner...for now 😁