YR5 project Update 21/04/09 - Job done!!!!

Blau Zedong · Banned Joined: 26 Jun 2006 Karma :

Spent past two days working flat out on the heap. BT45's on (after puncturing two brand new inner tubes Evil or Very Mad

), forks back on - basically to rolling chassis stage. Also got new fork seals and swingarm bushes. So pleased with myself I cracked on - mounted handlebars, clocks, wiring harness and then swore lots because the battery box design is totally shite.

Just got engine to reassemble, wiring to plumb in and a better paint job and we are rolling! Cool

https://i5.photobucket.com/albums/y164/BLUEX5/DSC00020.jpg

This weekend I have mainly been concocting a homebrew paintjob to replace the tasteful tangerine colour the previous owner saw fit to inflict on the world.

https://i5.photobucket.com/albums/y164/BLUEX5/DSC00025.jpg

https://i5.photobucket.com/albums/y164/BLUEX5/DSC00024.jpg

Just headlight shell and brackets to do, and some Yamaha tuning forks stickers for tank to slap on.

Mate of mine came round this morning and christened it the "Silver Dream Racer" as everything on it is either silver / chorme or black, although I'll pass on listening to David Essex while working on it Confused

.

Paint is from Halfrauds cans, obviously less than perfect but given time and budget constraints isn't too bad.

https://i5.photobucket.com/albums/y164/BLUEX5/DSC00023.jpg

Crap Pic but a reminder of how orange the tank actually was!

Hey ho....engine rebuild next weekend............
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18:54:48 Rob Fzs: jews don't give away stuff for free

18:54:59 Rob Fzs: unless its their clothes/ hair/ golden teeth

Gazdaman · I did a trackday!!! Joined: 12 Aug 2004 Karma :

Looking good, look forward to reading more! With more photos.

Gaz

andrew · Mister Road Rage Joined: 03 Feb 2002 Karma :

Looks top. Got any more pics?

Blau Zedong · Banned Joined: 26 Jun 2006 Karma :

Engine getting built next weekend, might do an update after that unless people like to see pictures of metal bits in primer.
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18:54:48 Rob Fzs: jews don't give away stuff for free

18:54:59 Rob Fzs: unless its their clothes/ hair/ golden teeth

garth · World Chat Champion Joined: 15 Dec 2004 Karma :

Blau Zedong · Banned Joined: 26 Jun 2006 Karma :

Tank Grafix on Very Happy

https://i5.photobucket.com/albums/y164/BLUEX5/DSC00027.jpg

https://i5.photobucket.com/albums/y164/BLUEX5/DSC00026.jpg
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18:54:48 Rob Fzs: jews don't give away stuff for free

18:54:59 Rob Fzs: unless its their clothes/ hair/ golden teeth

Blau Zedong · Banned Joined: 26 Jun 2006 Karma :

**Update 29/5/07**

It runs! However there are several problems -

Charging system isn't playing AT ALL.

Exhaust downpipes are holier than swiss cheese despite looking ok.

Caburation needs major fettling (VERY lean at closed / part throttle) so response and idle is pot luck). However you have the time it takes the battery to go flat and drop a cylinder to fettle it....very annoying.

"Unobtainable" throttle cable isn't due for another week so has a tatty old one one it - oil pump adjuster f**ked, but killing off a few litres of premix so not a huge issue.

Still a million and one other jobs to do - fit chain, spray front guard, sort out disco indicators etc etc.

It's getting a holiday at a mate's workshop to get finished off I think. I need a second head to look at some of these issues.

https://i5.photobucket.com/albums/y164/BLUEX5/DSC00031.jpg

https://i5.photobucket.com/albums/y164/BLUEX5/DSC00030.jpg
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18:54:48 Rob Fzs: jews don't give away stuff for free

18:54:59 Rob Fzs: unless its their clothes/ hair/ golden teeth

Gazdaman · I did a trackday!!! Joined: 12 Aug 2004 Karma :

Looks like you've done a lovely job so far. Keep at it!

Gaz

shaun_04 · Brolly Dolly Joined: 06 Aug 2005 Karma :

I liked the old "tangerine" colour, oh well.

How much has the project cost you so far ?

Blau Zedong · Banned Joined: 26 Jun 2006 Karma :

Cost????? Too much!!!! At Stafford last year I could of bought a tidy one, in standard paint with new pistons, year's MOT etc for £850.

I'll have a go at costing it since you asked -

Bike - £475

Indicators - £35.10

One big order of misc bits - Chain, inner tubes etc etc - £131.91

Top end - £112.99

Another Order of misc bits - £147.90

Engine oil seals / studs / fastners - £94

Fork Seals / Swing arm bushes - £40

Tyres - £121.90

Total circa £1158.79 - but i think a few bits have flown under the radar (cables etc) that I can't find receipts for.

There is a lesson to be learnt here - NEVER assume anything about a bike that has been stood for 16 years, regardless of external condition and history.

Also - If you want a certain bike - just bloody buy one that works to start with!
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18:54:48 Rob Fzs: jews don't give away stuff for free

18:54:59 Rob Fzs: unless its their clothes/ hair/ golden teeth

Blau Zedong · Banned Joined: 26 Jun 2006 Karma :

https://s5.photobucket.com/albums/y164/BLUEX5/?action=view¤t=MOV00032.flv

Crap clip of the damn thing running I took messing around over the weekend! Still - both cylinders firing - but a lot of work to do to get the jetting right (more jets on order Confused

).

Bit crap you can't embed clips on here.
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18:54:48 Rob Fzs: jews don't give away stuff for free

18:54:59 Rob Fzs: unless its their clothes/ hair/ golden teeth

jimbothe · World Chat Champion Joined: 29 Sep 2006 Karma :

Blau Zedong · Banned Joined: 26 Jun 2006 Karma :

owdamer · World Chat Champion Joined: 06 Oct 2004 Karma :

Looks good. I know what you mean about sourcing parts. I'm still trying to restore my 94 yzf750 to its original condition and getting parts is a joke. I've been looking for a fairing panel for over 2 years now. I can buy a new un for about £300 but I dont have that kind of dosh. You can get a good running bike for about £1000 on ebay but they're always the early pinkys, never ones the same colour as mine. One the rare occasions one the same as mine comes up its always had a tumble on the same side as mine has.

Blau Zedong · Banned Joined: 26 Jun 2006 Karma :

Fixed the charging circuit today (dead rectifier) and have actually ridden the damn thing...only up and down a mates drive though. By christ it's loud - can't have a conversation over it ticking over! Needs a new throttle cable, appropriate bars and a set of exhaust mounts (oh - and an MOT).
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18:54:48 Rob Fzs: jews don't give away stuff for free

18:54:59 Rob Fzs: unless its their clothes/ hair/ golden teeth

palmer · Fiddled Kiddy Joined: 21 Jul 2004 Karma :

single seat, clip ons, fly screen.

coool Laughing

Blau Zedong · Banned Joined: 26 Jun 2006 Karma :

The black pig is finished. Taxed (free) on monday - using it for work all week, if it behaves it goes to Ashbourne on friday. Rides nicely - for an educated guess the jetting is good, as strokers go there is lots of torque and response. Induction noise is shattering - like having someone bellowing in your ear. Still running it in so no major thrashage, although i did blip it up to 9K in second tonight (glaze busting Confused

) and it sounded like a stuck pig - fantastic! Overall gearing seems a bit tall so once run in and jetting optimised might need to knock a tooth of the front sprocket. More pics to follow - only bugger is that Halfords petrol proof lacquer isn't Sad

.
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18:54:48 Rob Fzs: jews don't give away stuff for free

18:54:59 Rob Fzs: unless its their clothes/ hair/ golden teeth

Blau Zedong · Banned Joined: 26 Jun 2006 Karma :

https://i5.photobucket.com/albums/y164/BLUEX5/DSC00044.jpg

Crying or Very sad

Oil pump failure......
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18:54:48 Rob Fzs: jews don't give away stuff for free

18:54:59 Rob Fzs: unless its their clothes/ hair/ golden teeth

.Chris. · World Chat Champion Joined: 09 Jun 2007 Karma :

Oops, what's the barrel like?
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Chris
1985 Kawasaki Z550F

Blau Zedong · Banned Joined: 26 Jun 2006 Karma :

.Chris. · World Chat Champion Joined: 09 Jun 2007 Karma :

Ah, not enough oil then I assume?

Hope it all gets sorted without too much wallet pain. Very Happy

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Chris
1985 Kawasaki Z550F

Blau Zedong · Banned Joined: 26 Jun 2006 Karma :

The long story is that the 250 pump will flow enough volume with modern oils, but the drive gear pitch is different......works when fitted but after a few miles strips the gear. Bit like wrong pitch nut on a thread....you might get it started but it'll chew the thread. The pumps are colour coded and I didn't check the code before fitting it.
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18:54:48 Rob Fzs: jews don't give away stuff for free

18:54:59 Rob Fzs: unless its their clothes/ hair/ golden teeth

Blau Zedong · Banned Joined: 26 Jun 2006 Karma :

Not much to report, new pistons and rebore were needed, gearing sorted etc, then I bought another Gixxer 750 so got sidetracked and left the old Yam in the shed.

Did find out it wasn't charging last time I fired it up, so a modern reg / rec has been purchased as I'm not farting about diagnosing bits that look like they came from the WW2 Enigma machine....

Anyway, bought these pipes (Vintage allspeeds) last year for 20 quid. Solid put with a few dents, last week spent some time filling the worst of the dents with epoxy resin and sanding back to profile. Bit of BBQ paint and this is the result -

https://i5.photobucket.com/albums/y164/BLUEX5/DSC00058.jpg

https://i5.photobucket.com/albums/y164/BLUEX5/DSC00057.jpg

https://i5.photobucket.com/albums/y164/BLUEX5/DSC00056.jpg

They look better than the stock pipes, and hopefully they will be noisy enough to get me an ASBO.

Can't wait to sort the electrical stuff and fire it up!

Also popped some bigger main jets in - 220's up from 200's, hopefully it won't need too much fettling to get right.
____________________
18:54:48 Rob Fzs: jews don't give away stuff for free

18:54:59 Rob Fzs: unless its their clothes/ hair/ golden teeth

TUG · World Chat Champion Joined: 12 May 2007 Karma :

When can i have a go?
That bike is sooooo nice....
A question on the seat, is it a custom or do they come standard like that? And where could i get one or make one for my CG project?
Excellent work mate.
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Haz ER-5, innit!

Blau Zedong · Banned Joined: 26 Jun 2006 Karma :

Cheers

The seat is a Gulari?, bought new old stock off egay for a considerable sum. I had one on my purple 350 and it looked teh sex despite being hard as wood, so couldn't resist the chance accquire a new 'un for this project. The firm did 2/4 seats for lots of 70's and 80's Jap bikes. You could try sourcing a tatty one second hand and butchering it to fit the CG, then if it works out you can get it recovered etc.

Quite eager to have a go myself mate - but still got paint to sort and few other small jobs before firing it up and getting it back on the road.
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18:54:48 Rob Fzs: jews don't give away stuff for free

18:54:59 Rob Fzs: unless its their clothes/ hair/ golden teeth

YR5 project *Update 21/04/09* - Job done!!!!

YR5 project Update 21/04/09 - Job done!!!!