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Tool Girl Holley's DR200 project

With the goal of riding the little DR the full length of New Zealand, we decided to do a 'from the ground up' rebuild, Follow Holley & myself on this awesome project broken down into many videos...

Exhaust & a few other bits to fit then we can see if she will run!!

By Andy Mechanic on 4 February 2021

It's been a crazy busy weekend for Holley & I but the little DR is coming on nicely. Just a few more parts to fit &, fingers crossed, the little engine will fire up!

Join Holley & myself in another Episode covering the full rebuild (excluding the engine) of a DR200 farm bike special. I'll be covering an engine rebuild at some point during 2021 I'm sure.

Enjoy Andy & Holley

Parts Worked On: 

  • Chassis

Time to install the wiring harness & all those electrical thingy-ma-bobs!

By Andy Mechanic on 4 February 2021

With the front end installed & the engine in it's time to transplant the wiring harness from the old to the new frame. A relatively simple task until Holley & I realize that it seems the loom is one of the first items to be fitted to the frame in the factory & we now have an air box & engine in the way! 

Parts Worked On: 

  • Electrical System

Rear suspension linkage bearing replacement

By Andy Mechanic on 4 February 2021

If I'm been honest I have been putting this job off for a while, but since Holley is in the shop helping out this weekend there is now no excuse to delay any longer!!! Join Holley & me for another Episode in the rebuild on her awesome Suzuki DR200 Farm bike 'Special'....

Parts Worked On: 

  • Chassis

Fitting the engine to the newly painted frame...

By Andy Mechanic on 4 February 2021

Join Holley & myself as we build up her new Suzuki DR200 Farm Bike special, in this Episode we remove the engine from the original frame & install into the new, painted frame. The next step in completing this epic build...

Parts Worked On: 

  • Engine

Front end rebuild on Holley's DR200 - a new frame!

By Andy Mechanic on 4 February 2021

With the new frame shot blasted & painted it's now time to swap everything across - no easy task & with a few extra jobs along the way this is going to be a busy weekend with Tool Girl Holley... So, in this video we swap across the front end, including the fitment of new steering head bearings - you'll see why in the video! Watch out for the future Episodes in this series.... Enjoy Andy & Holley

Parts Worked On: 

  • Chassis

A new right hand side stand! Why???

By Andy Mechanic on 4 February 2021

Now I know it's only a short video but, well, some viewers do complain that my videos are waaaaayyyyy to long! The next step on the 'to do' list is fit the new right hand side stand - an easy task, yes, but one which can be really difficult if you don't know the 'easy' way of getting that strong spring on! Besides, any video featuring Tool Girl Holley is an awesome video in my book! Enjoy Andy

Parts Worked On: 

  • Chassis

Fitting the new footpegs & mounts - Tool Girl Holley

By Andy Mechanic on 4 February 2021

Just working our way through the huge list of jobs to get done on this awesome Suzuki DR200 farm bike - in this video we get our heads around how to fit the Genuine Suzuki Footpegs, internal rubber dampers & mounts - the job turned out a little more complex that we initially thought! Enjoy Andy & Holley...

Parts Worked On: 

  • Chassis

Swing arm bearing replacement - this'll be fun!

By Andy Mechanic on 4 February 2021

Just like all the other bearings & bushes in this little bike these need replacing - not a difficult job provided the swing arm bolt behaves itself! Join Tool Girl Holley & me in this next Episode in the Series covering the repairs on Holley's Farm Bike...

Parts Worked On: 

  • Chassis

Holley replaces the rear wheel bearings on her DR200

By Andy Mechanic on 4 February 2021

Working our way through the looooooong list of repairs on Tool Girl Holley's DR200 Farm bike, this video covers the replacement of the rear wheel bearings - a simple enough job if you know what you are doing but a job non-the-less that needs to be done right & will put Holley's bike one step closer to been on the road!

Parts Worked On: 

  • Chassis

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