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2003 R1 5PW Rebuild (Pic heavy)

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tom_e
Traffic Copper



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PostPosted: 12:26 - 03 Mar 2017    Post subject: Reply with quote

In excess of 260C according to a quick Google.
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Nope.
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PostPosted: 16:10 - 04 Mar 2017    Post subject: Reply with quote

tom_e wrote:
In excess of 260C according to a quick Google.


Hmm, that doesn't seem high enough for something that's going to be IN my cylinder head :/

Little bit more progress:

Got a new top yoke:

https://c1.staticflickr.com/4/3919/33089333552_9eda4f0f50_z.jpg

Test fit:

https://c1.staticflickr.com/3/2872/32862592530_26a6d762e7_z.jpg

Bars on:

https://c1.staticflickr.com/4/3762/33089326062_cccf5dd1ca_z.jpg

Brakes on:

https://c1.staticflickr.com/1/610/33117297541_476399a0b6_z.jpg

Master cylinder on:

https://c1.staticflickr.com/1/611/33117293311_167f7500ea_z.jpg

Rear set test fit:

https://c1.staticflickr.com/1/666/32862596230_3e7073f3db_z.jpg

Next job, make a new rear set brake lever:

https://c1.staticflickr.com/4/3888/33203996566_4750c7484c_z.jpg
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2011 XT660Z Ténéré - 2003 YZR-R1 5PW (In Build)
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Fizzer Thou
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Joined: 06 Aug 2011
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PostPosted: 10:45 - 05 Mar 2017    Post subject: Reply with quote

Nope. wrote:
chris-red wrote:
Assuming AIS is some kind of Secondary Air thing. It might be worth wrapping those plugs in PTFE tape.


Not a bad shout, but a bit concerned about putting PTFE tape in the head that close to the exhaust port. What sort of temperature can it withstand?


I used high temperature epoxy when I installed blanking plugs after removing the AIS air pump on my R1 5JJ

http://i1073.photobucket.com/albums/w384/Rhencullen5/R1%20Engine%20Rebuild/Picture114.jpg
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Nope.
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PostPosted: 20:31 - 05 Mar 2017    Post subject: Reply with quote

Fizzer Thou wrote:

I used high temperature epoxy when I installed blanking plugs after removing the AIS air pump on my R1 5JJ


That's not a bad shout, thanks! Thumbs Up
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Nope.
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PostPosted: 22:35 - 06 Mar 2017    Post subject: Reply with quote

Thought I'd better check that the lock set fits the new top yoke and the steering lock works etc. so I drilled out the security bolts from the old top yoke, pulled the lock set off and test fitted it to the new yoke:

https://c1.staticflickr.com/4/3668/32910245690_0a5fccb0f3_z.jpg

This let me align the steering lock etc. and make some measurements for spacer sizing.

https://c1.staticflickr.com/3/2905/32910245030_c59a27d423_z.jpg

Having measured this up I hopped on the lathe and quickly turned up some spacers:

https://c1.staticflickr.com/3/2820/33164988691_64d18b1051_z.jpg

https://c1.staticflickr.com/1/689/32478595033_a30e4a0631_z.jpg

Got it all fitted with temporary bolts:

https://c1.staticflickr.com/3/2830/32478593543_3f6e72f885_z.jpg

Just got to turn up some lower spacers and possibly make some new bolts.
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talkToTheHat
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Joined: 21 Feb 2012
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PostPosted: 01:07 - 09 Mar 2017    Post subject: Reply with quote

Do the ais plugs seal on the tip or the thread? You do not want to be sealing on a thread if you can help it. Given the choice i would seal on the underside of a cap head bolt and use a copper crush washer. Where do the plugs screw into and what went in there previously?

You've probably got enough heat soak through the engine casing to not burn the ptfe that's compressed in the threads. I would assume the high temp epoxy isn't as capable of high temperatures as ptfe, but if it goes really hot I want to know what it is and who supplies it.
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Nope.
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PostPosted: 22:33 - 09 Mar 2017    Post subject: Reply with quote

talkToTheHat wrote:
Do the ais plugs seal on the tip or the thread? You do not want to be sealing on a thread if you can help it. Given the choice i would seal on the underside of a cap head bolt and use a copper crush washer. Where do the plugs screw into and what went in there previously?

You've probably got enough heat soak through the engine casing to not burn the ptfe that's compressed in the threads. I would assume the high temp epoxy isn't as capable of high temperatures as ptfe, but if it goes really hot I want to know what it is and who supplies it.


They seal on the thread, they screw into holes that previously held interference fit hoses like so:

http://www.robcollingridge.com/kitcar/design/engine/AIS_Stub.jpg

This stuff claims to withstand temperatures up to: 1316°C, but I'm not sure I believe that! http://www.ebay.co.uk/itm/Blue-Magic-Quiksteel-Thermosteel-High-Temperature-Metal-Repair-Epoxy-Putty-3oz-/401216754107?hash=item5d6a61d1bb:g:macAAOSw5cNYFfMi
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ben17484
L Plate Warrior



Joined: 06 Mar 2017
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PostPosted: 09:28 - 10 Mar 2017    Post subject: Reply with quote

Good project this. Looking forward to more pics and progress.
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chrisdubya
Scooby Slapper



Joined: 05 Jun 2015
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PostPosted: 10:12 - 10 Mar 2017    Post subject: Reply with quote

Following Thumbs Up

Had my first ride on my newly acquired 5PW last weekend - such a good bike!!
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talkToTheHat
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PostPosted: 23:55 - 11 Mar 2017    Post subject: Reply with quote

Personally, I would leave the hose stubs in and plug those. I wouldn't plug an aluminium head with epoxy, especially "magic" epoxy that claims to be stable (yeah right) at about twice the melting point of your head.

Those hose stubs will have non-standard tapered threads. let them do their job and take the easy way out by plugging the relatively inexpensive part with the complex and hard to replicate thread. The whole point of tapered threads (ok, other than being a good gas seal) is scaring away people who arent core design team so they don't mess. Use the stubs you've been given and be thankful you have them.
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Fizzer Thou
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Joined: 06 Aug 2011
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PostPosted: 19:50 - 12 Mar 2017    Post subject: Reply with quote

Nope. wrote:
talkToTheHat wrote:
Do the ais plugs seal on the tip or the thread? You do not want to be sealing on a thread if you can help it. Given the choice i would seal on the underside of a cap head bolt and use a copper crush washer. Where do the plugs screw into and what went in there previously?

You've probably got enough heat soak through the engine casing to not burn the ptfe that's compressed in the threads. I would assume the high temp epoxy isn't as capable of high temperatures as ptfe, but if it goes really hot I want to know what it is and who supplies it.


They seal on the thread, they screw into holes that previously held interference fit hoses like so:

http://www.robcollingridge.com/kitcar/design/engine/AIS_Stub.jpg

This stuff claims to withstand temperatures up to: 1316°C, but I'm not sure I believe that! http://www.ebay.co.uk/itm/Blue-Magic-Quiksteel-Thermosteel-High-Temperature-Metal-Repair-Epoxy-Putty-3oz-/401216754107?hash=item5d6a61d1bb:g:macAAOSw5cNYFfMi


That epoxy is the stuff that I used.And I did not use it to plug the AIS holes in the cylinder head,but to permanently seal the tapered plugs that I machined in a lathe.They work perfectly and have been in place for about 15,000 miles.The taper of the original feed pipes was not that difficult to replicate and preferable to filling the original adapters with anything Thumbs Up
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Nope.
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Joined: 16 Feb 2011
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PostPosted: 21:57 - 14 Mar 2017    Post subject: Reply with quote

Fizzer Thou wrote:

That epoxy is the stuff that I used.And I did not use it to plug the AIS holes in the cylinder head,but to permanently seal the tapered plugs that I machined in a lathe.They work perfectly and have been in place for about 15,000 miles.The taper of the original feed pipes was not that difficult to replicate and preferable to filling the original adapters with anything Thumbs Up


Cool, thanks. Ordered Thumbs Up. Yeah I've machined the above plugs for my head and tapped the holes out for them to screw into so it sounds like we had the same thought!

Got my Barnett Carbon Fibre clutch out of it's box and got all excited:

https://c1.staticflickr.com/3/2926/33270918452_3dce9f3ee4_z.jpg

Machined some washers:

https://c1.staticflickr.com/1/645/33426651355_386ffd7d2a_z.jpg

Test fitted the lock set:

https://c1.staticflickr.com/4/3709/33058495580_bf5380ec9b_z.jpg

Fitted and locktite'd in!

https://c1.staticflickr.com/1/576/33058497190_e453886970_z.jpg

All fitted and aligned:

https://c1.staticflickr.com/4/3708/33058497640_4a9015d9fd_z.jpg

Dropped the sump and fitted the sump gasket:

https://c1.staticflickr.com/1/612/33441638635_d8091038e3_z.jpg

Mmmmm oil pickup goodness:

https://c1.staticflickr.com/1/593/33441639605_95e6530e3d_z.jpg

Got the sump gasket all fitted, sump back on and all torqued up.

Little bits but it's moving along...
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2011 XT660Z Ténéré - 2003 YZR-R1 5PW (In Build)
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Nope.
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PostPosted: 21:35 - 15 Mar 2017    Post subject: Reply with quote

Bit more!

Found the engine water pump fitting that I'd misplaced and cleaned it up:

https://c1.staticflickr.com/4/3786/32648140603_d3614b97c0_z.jpg

https://c1.staticflickr.com/1/588/32648140793_5c12a975d5_z.jpg

Fitted a new O-Ring:

https://c1.staticflickr.com/1/698/32648141173_09812f0bc2_z.jpg

https://c1.staticflickr.com/4/3690/32648141813_f7f373c70c_z.jpg

Installed it in the bike:

https://c1.staticflickr.com/1/739/32648143583_c02815995b_z.jpg

Found the cylinder head coolant pipes and thermostat:

https://c1.staticflickr.com/4/3699/32648144813_a2112786f9_z.jpg

https://c1.staticflickr.com/1/760/32648146283_b9a761cd58_z.jpg

Perished O-Ring:

https://c1.staticflickr.com/4/3902/32648148073_87014c725f_z.jpg

Fitted the silicon hoses to the front of the engine:

https://c1.staticflickr.com/1/747/32648149473_c3db4e9733_z.jpg

Cleaned up the engine pipes and thermostat and fitted the silicon hoses:

https://c1.staticflickr.com/4/3954/33079085680_39e1f19492_z.jpg

Dribs and Drabs Very Happy
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Nope.
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Joined: 16 Feb 2011
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PostPosted: 22:23 - 16 Mar 2017    Post subject: Reply with quote

Took a look at the Radiator tonight. Mine was damaged so I bought a part from a breaker. It needs a bit of tidying up:

https://c1.staticflickr.com/4/3948/33325147702_e1ff3b59d6_z.jpg

Not gonna spend a huge amount of time on this. I started stripping the loose coating off the edges, I covered the vanes with cardboard so they didn't get damaged by the wire wheel:

https://c1.staticflickr.com/1/660/32637671194_0831f6ff36_z.jpg

I didn't get a photo of it stripped off but I cleaned up the vanes a bit with a toothbrush and then masked up the ends and dusted over the front of the vanes (yes I'm aware this could decrease the cooling ability of the radiator but the paints only a thin coat):

https://c1.staticflickr.com/4/3888/32637673634_05d52217df_z.jpg

I'll be painting the ends when I've done the back Thumbs Up
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Nope.
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PostPosted: 20:22 - 19 Apr 2017    Post subject: Reply with quote

Okay so I've not been in the country for more than 3 days at a time really since the last update Cool

I did manage to get the thermostat fitted though:

https://c1.staticflickr.com/3/2878/34145588565_facec57c58_z.jpg

I've also been painting the radiator, more on that when it's done!
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Nope.
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PostPosted: 16:09 - 22 Apr 2017    Post subject: Reply with quote

I've done a bit more work today Smile

Got the painted radiator out:

https://c1.staticflickr.com/3/2808/33388422783_829e831c00_z.jpg

https://c1.staticflickr.com/3/2814/34068292361_f40789f513_z.jpg

Decided to paint the other radiator fixings so I took the fan bracket off the fan unit:

https://c1.staticflickr.com/3/2841/34041870082_3de18c674a_z.jpg

https://c1.staticflickr.com/3/2863/34158219196_6607e1fae4_z.jpg

Wire wheeled the horn back:

https://c1.staticflickr.com/3/2945/33388422173_0286260861_z.jpg

Sprayed the horn and the radiator cap:

https://c1.staticflickr.com/3/2885/34068298091_a2a66ccc1b_z.jpg

Sprayed the fan bracket:

https://c1.staticflickr.com/3/2891/33388434523_6d40082c1c_z.jpg

Freshly painted radiator fixings:

https://c1.staticflickr.com/3/2899/33814883910_3d868bb046_z.jpg

Re-fitted the fan and coolant bottle:

https://c1.staticflickr.com/3/2881/34041868822_a5b791faa8_z.jpg

Fitted the horn:

https://c1.staticflickr.com/3/2902/34068286061_76415bf2b0_z.jpg

Got the exhaust out, it was rather mucky:

https://c1.staticflickr.com/3/2876/33388424383_3e2d19a04b_z.jpg

https://c1.staticflickr.com/3/2886/33388427283_c2be24f242_z.jpg

https://c1.staticflickr.com/3/2897/34041884562_23b1ec5686_z.jpg

https://c1.staticflickr.com/3/2945/34199047865_4fc28eab89_z.jpg

I cleaned it up (alloy wheel cleaner is great for cleaning titanium exhausts in case you're wondering!), and got it fitted:

https://c1.staticflickr.com/3/2806/33814896720_9814cecd4e_z.jpg

I also hung the radiator off the top bracket.

https://c1.staticflickr.com/3/2881/34041891352_dd3eaf4508_z.jpg

https://c1.staticflickr.com/3/2864/33388421683_7a6096624a_z.jpg

https://c1.staticflickr.com/3/2947/33814883600_76b41331af_z.jpg

I had to fit the right hand pillion peg to hang the end can from, so thats on now as well. Hoping to get the cooling system all plumed in tomorrow Thumbs Up
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Nope.
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PostPosted: 21:24 - 19 Jun 2017    Post subject: Reply with quote

Okay! So a little update due. To be honest I haven't made a whole lot of progress because I've been galavanting around, most recently at the TT:

https://c1.staticflickr.com/5/4220/35282926211_8585141d82_z.jpg

https://c1.staticflickr.com/5/4245/35246043622_06f1eebd6b_z.jpg

https://c1.staticflickr.com/5/4241/35025423190_631f98d0b2_z.jpg

https://c1.staticflickr.com/5/4275/35246044482_d3340f33d5_z.jpg

Did a full service on it and had the chain/sprockets changed before I went as well:

https://c1.staticflickr.com/5/4247/35246046582_281522f929_z.jpg

But I digress, back to the 5PW! A bits happened, I've put the battery tray back in the subframe and started installing the wiring loom. I hit a snag with the new engines magneto though, as the connector on the new magneto looked like this:

https://c1.staticflickr.com/5/4281/35025398020_c69c04306d_z.jpg

And the original one looked like this:

https://c1.staticflickr.com/5/4247/35025396960_6ef3f99c30_z.jpg

No bother though, it's 3 phase into the reg/rec so I just chopped the connector off the old magneto and spliced it onto the new one:

https://c1.staticflickr.com/5/4212/35025393700_02799f4f7e_z.jpg

Sorted!

https://c1.staticflickr.com/5/4277/35025391210_bb1e79e311_z.jpg

I've also received and painted the lower radiator mount as I seem to have misplaced it during dismantling. I'm awaiting the delivery of some plastic push rivets to put some of the radiator surround plastics and ducting plastics in as the fairing ones are a different size, but once they're in I'll be able to fully install the cooling system. I've already put the spark plugs in so then I'll be able to install the coil packs, complete the engine wiring, put the throttle bodies on, fit the clutch, fit the oil filter, fill the oil and coolant up, sort the fuel tank out and fit that and then I can fire it up!

Not long to go now hopefully!
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