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Project TTaRt up!

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Fladdem
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Joined: 29 Jun 2011
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PostPosted: 15:26 - 04 Jan 2015    Post subject: Project TTaRt up! Reply with quote

So, I got my hands on a CRM 250. What do I do with the old Yam? Blow money on it of course!

So, the top shock bushes are worn out, and the shock no long does any absorbing, all the oil and gas has seeped out and gone. The engine is burning oil as well as leaking oil from every gasket. Considering the sump holds about a litre, there's not a lot of wiggle room for oil loss, it actually used more oil than the CRM! Laughing

So, without any forethought or planning, or even a wash, which is making everything difficult, I started tearing stuff off, the side panels, seat, tank, subframe, airbox, and then the shock. I didn't take pics of this, because, like I said I was bored during my holiday time off.

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/PC180227_zps27830b3d.jpg

Could be engine oil, or oil from the shock

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/PC180228_zps657872b3.jpg

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/PC180229_zps3b696ff3.jpg

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/PC180230_zpsdc61ae90.jpg

One thing I will do is hunt down an original indicator lens, after losing the right hand side at Daventry MX track back in September, I bodged a lens on from the box of Landy spares. Laughing

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/PC180231_zps434ba931.jpg

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/PC180232_zps22629dc7.jpg

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/PC180233_zps2dff2835.jpg

Shock off, sent it away to a specialist to get set-up for me as well, while I'm at it. I don't know how to do suspension either, I was scared to touch it really.

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/PC180234_zps9e990a56.jpg

Worn top-bush

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/PC180235_zps0ba631ec.jpg

Oil out, front mudguard off for more space, pipe off

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/PC180238_zpsb3cbe78c.jpg

Rocker cover off, note cable tie around cam chain so I don't lose it in the crank case! I'd replace the chain, but I only did it 7,000KM's ago, last time I tore into the engine to do the big-bore and other engine nonsense in the quest for MOAR POWAH!

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/PC310245_zps61c725eb.jpg

Cams off

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/PC310246_zps81d8528b.jpg


Cylinder-head off

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/PC310248_zps9d71d1da.jpg

She's running a bit hot! Shocked I'm going to have to re-jet her a lot richer, I'm not sure if the exhaust valves are salvageable yet

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/PC310249_zps3900d882.jpg

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/P1030255_zpsb4b04bf2.jpg

Bore's still ace from the re-bore last time

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/PC310251_zps33c5f373.jpg

Rings look like they're sealing, must be the valve stem seals, which I didn't change last time, although should have done, but I tried to scrimp the first time, which is why I'm back in there again. Brick Wall

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/PC310252_zps2a830254.jpg

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/PC310253_zps44f3ce39.jpg

Cleaned the piston face up, a touch of autosol and wire wool of various grades.

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/P1030254_zps706aba4d.jpg

Then went on a rampage and did the oil filter cover as well. Embarassed

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/P1030258_zpse233c34c.jpg

So, I've got some gaskets for stuff, new valve stem seals, new piston rings, because why not? I'm in there anyway. I'm going to do the clutch while I'm at it, it's starting to slip a bit now, a trip to Shrewsbury in the summer with M1ke and rhys1005 off here on a Husaberg 450 and a KTM 300 respectively killed the clutch on the hills trying to chase them down, I lost all drive on one hill and had to wait for twenty minutes for the bike to cool down again before I could carry on, and now it's getting gradually worse.

I'll do the swinging arm bearings, I did the linkage bearings not too long ago, actually transpires it was back in April!

http://i1302.photobucket.com/albums/ag134/Fladdem/1545775_10201016702740040_7392258005290048820_n_zpsd5f633ff.jpg

And, I hate to say it, but I think I'm going to go nuts with wire wool and autosol on all aluminium bits, put the engine back together, then drop it out the frame, get everything else off and get the frame powdercoated purple. Maybe even hunt down some fresh plastics and just use it as a road-going bike. Embarassed

Anyway, wish me luck! It should be easier to do than my GPZ, because I can work on this in the garage, so I'm not dependant on the weather when working.
____________________
Current:1991 Honda MT50 (Soon to be a H100/MTX/MT5 hybrid), 1976 Honda Cub C70, 2005 Honda Varadero 125, 1993 Yamaha TTR250 Open Enduro , 2010 Road Legal Stomp YX140, 1994 Honda CRM 250 MK III, 1999 Cagiva Mito 125, 1992 Honda CB400 Super Four, Stomp T4 230, 1984 Honda H100s, 2009 Sym XS125K
Past:2003 Aprilia RS125, 1982 Kawasaki GPZ550(FREE BIKE!)
I'm having more fun than a well-oiled midget.


Last edited by Fladdem on 17:02 - 04 Jan 2015; edited 1 time in total
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KLR600
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PostPosted: 15:52 - 04 Jan 2015    Post subject: Re: Project TTaRt up! Reply with quote

Fladdem wrote:
...Maybe even hunt down some fresh plastics and just use it as a road-going bike. Embarassed ....


Why not see if you can get some TZR125 wheels to fit? The later TZR125's ran 17" wheels front and rear so you'd have a much better choice in road tyres. Obviously it's never going to be a mad supermoto but I'd imagine it would be better for road riding if that's what you were going to use it for mostly.

You'll probably miss these but there are others on there for around 50 a pair. Not sure if you know anyone who can knock up some spacers and maybe some brake brackets but maybe worth a look?
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Fladdem
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PostPosted: 16:13 - 04 Jan 2015    Post subject: Reply with quote

DT125X wheels bolt straight up. Only problem is that yoofs want 'em for their DTR125's so they're expensive. I have two sets of wheels for it anyway, one got my crazy mad knobblies(!) and the other set on the bike has got a distanzia on the bake and a conti-escape on the front. I had a continental conti-escape on the back and I think it was great for my needs at the time.

But TZR wheels is a good idea, surely they must go on a DT which should mean they'll bolt up to mine, I'll look into it though, it could do with more brake up front as well.
____________________
Current:1991 Honda MT50 (Soon to be a H100/MTX/MT5 hybrid), 1976 Honda Cub C70, 2005 Honda Varadero 125, 1993 Yamaha TTR250 Open Enduro , 2010 Road Legal Stomp YX140, 1994 Honda CRM 250 MK III, 1999 Cagiva Mito 125, 1992 Honda CB400 Super Four, Stomp T4 230, 1984 Honda H100s, 2009 Sym XS125K
Past:2003 Aprilia RS125, 1982 Kawasaki GPZ550(FREE BIKE!)
I'm having more fun than a well-oiled midget.
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KLR600
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PostPosted: 16:56 - 04 Jan 2015    Post subject: Reply with quote

Yeah I'd have thought the DT SM wheels go for a lot because of all the kids on their DTR's and the look of spoked wheels being popualr with custom bike builders. I think I could quite easily get over the look of cast wheels on an supermoto if it saved me 250 though Laughing

I'm sure G will be along soon to say that normal road biased tyres in off road wheel sizes are fine and that he was able to get his knee down on such tyres on his old DR600 so it's all a bit moot anyway Laughing Laughing

Cool project though. I will have another trailie at some point. Also a supermoto, MX bike, supersports, tourer...
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Now: '00 Kawasaki ZRX1100R - Past: '84 Yamaha DT125, '89 Kawasaki KLR600, '97 Yamaha XJ600N
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Fladdem
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PostPosted: 23:59 - 07 Jan 2015    Post subject: Reply with quote

You're as bad as me, I want a proper MX bike, a soft-core enduro bike for green laning and enduro-ing, a big trailie, like a Dominator 650, for gentle laning and mostly road work, something like a TY250 for classic trials then a hooligan machine for supermoto-ing. Then a small screamer of a road-bike, like a mito or a 250 inline 4 and probably a TRX850. Oh, and my pit-bike and my MT5! Laughing Must get a farm at some point... Praying

So, I took my cylinder-head into work today, didn't get a lot done really, got the valves out, cleaned them up a bit and started trying to get some casting marks out the intake port Laughing All pictures were taken with my phone, I'll try again in my lunch break tomorrow for more stuff.

Valves out. I used a 13mm deep socket held squarely over the top of the valve spring, gave it a quick, but gentle tap with a hammer and the collars bounced out and allowed the springs to be removed to get the valves out. I haven't worked out how to put them back in yet without a valve spring compressor.

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/DSC_0031_zpsf93d65ca.jpg

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/DSC_0027_zpsca10d2af.jpg

Check out the exhaust valves at the bottom! Shocked

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/DSC_0029_zps07566721.jpg

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/DSC_0028_zpse1c5a6b5.jpg

After a clean up with the wire wheel, looks like new! (nearly)

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/DSC_0030_zpsec45857c.jpg

The valve stem seals were so loose, there was a lot of play and one valve even fell out as soon as the collar was removed. I'll put new seals in tomorrow or try to clean up the head a bit more in my lunch break.
____________________
Current:1991 Honda MT50 (Soon to be a H100/MTX/MT5 hybrid), 1976 Honda Cub C70, 2005 Honda Varadero 125, 1993 Yamaha TTR250 Open Enduro , 2010 Road Legal Stomp YX140, 1994 Honda CRM 250 MK III, 1999 Cagiva Mito 125, 1992 Honda CB400 Super Four, Stomp T4 230, 1984 Honda H100s, 2009 Sym XS125K
Past:2003 Aprilia RS125, 1982 Kawasaki GPZ550(FREE BIKE!)
I'm having more fun than a well-oiled midget.
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stevo as b4
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PostPosted: 18:57 - 08 Jan 2015    Post subject: Reply with quote

Interesting thread, and nice to see you showing that TTR some love too. All you need now is to get it back together and lets see something to really turn us on, the H100/MT5! Thumbs Up

It's cool that you can take your motor to work and use the Honda workshops and tools to get stuff done too! Fair play to them for letting you do that!

In my mind now, all I can think about is how long will it be before you really take advantage of that nice clean workshop and ramps etc, and build yourself a nice EF/EG Civic with a screaming spoon cammed B-series or shoe horn in a big block H22 on throttle bodies? Laughing

I'd love to get my Rover in there to fettle it and put my coilovers on!
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Fladdem
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PostPosted: 23:57 - 09 Jan 2015    Post subject: Reply with quote

stevo as b4 wrote:
Interesting thread, and nice to see you showing that TTR some love too. All you need now is to get it back together and lets see something to really turn us on, the H100/MT5! Thumbs Up

It's cool that you can take your motor to work and use the Honda workshops and tools to get stuff done too! Fair play to them for letting you do that!

In my mind now, all I can think about is how long will it be before you really take advantage of that nice clean workshop and ramps etc, and build yourself a nice EF/EG Civic with a screaming spoon cammed B-series or shoe horn in a big block H22 on throttle bodies? Laughing

I'd love to get my Rover in there to fettle it and put my coilovers on!


It's the H100/MT5 I'm most excited about as well. I'm still researching and planning, I want that one to be perfect. I'm also a little bit nervous, because I wasn't so confident on the spanners when I started planning and I think that fear is still with me a little bit, I can't really bring myself to start. Laughing

It's not so much they let me as they didn't stop me... Twisted Evil But everyone was interested, just had to hide it when the boss came in! I've just noticed the state of my bench in a picture as well Embarassed It's embarrassing.

So, I was late this morning, so as a result they took my lunch-break off me to save taking the wages off me. But yesterday, I was polishing the head some more, until about midnight! Laughing Which is why I overslept I reckon.

I pulled the valve stem seals off, again picture quality isn't great due to using my phone, but you'll get the idea.

Old one

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/P1080259_zps931e4eab.jpg

New one

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/P1080260_zps67adad87.jpg

Cylinder head last night.

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/P1080261_zpscfb0dad8.jpg

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/P1080264_zps47a24eff.jpg

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/P1080266_zps6b7441d2.jpg

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/P1080267_zpsb2d11da6.jpg

Not brilliant, but not too bad for an idiot with some wire wool and AutoSol... I'm content with that, in fact today, some of the other mechanics were impressed with the finish I'd achieved. If I was more confident with my knowledge of gas-flowing I'd have a go at re-shaping the ports as well.

I'm not really a big fan of Honda cars. I even think that the 2.2 I-DTEC engine feels more powerful than a 5 door EP3 shape Type S 2.0 petrol. Probably not, just more torquey, also the turbo is playing up on our runner MASSIVE LAG... I dunno though. I just want to get the Micra on the road to carry motorbike bits around easier.

I'm going in tomorrow, as the boss isn't working this Saturday, to try and build the cylinder head back up and bring it home before heading out in the afternoon for a spot of green laning on the CRM. It's great not doing coursework anymore!
____________________
Current:1991 Honda MT50 (Soon to be a H100/MTX/MT5 hybrid), 1976 Honda Cub C70, 2005 Honda Varadero 125, 1993 Yamaha TTR250 Open Enduro , 2010 Road Legal Stomp YX140, 1994 Honda CRM 250 MK III, 1999 Cagiva Mito 125, 1992 Honda CB400 Super Four, Stomp T4 230, 1984 Honda H100s, 2009 Sym XS125K
Past:2003 Aprilia RS125, 1982 Kawasaki GPZ550(FREE BIKE!)
I'm having more fun than a well-oiled midget.
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mysterious_rider
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PostPosted: 10:19 - 10 Jan 2015    Post subject: Reply with quote

I like this thread. Smile Smile doing a sweet job matey. Reminds me I need to (again) rebuild the zzr6 gearbox, and get it ready for some trackday fun.

I think i will do this in the summer Laughing
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Fladdem
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PostPosted: 20:45 - 15 Jan 2015    Post subject: Reply with quote

I finally managed to get a chance to play with my head again. Wink

I just ground the valve seals in today, I was going to do it yesterday lunch break but after being told we did have valve grinding paste, I spent 15 minutes looking for it, then another 45 minutes waiting for Leamoco to turn up with some and lost the whole lunch not doing anything productive. Crying or Very sad

Today, no time to waste, valves to be seated!

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/P1140269_zps3a449df4.jpg

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/P1140268_zps0620f769.jpg

I have done all four, took about an hour and a half, but I just had to sneak some valve grinding in when it quietened down in the afternoon. Laughing The exhaust valves took a lot of effort to get going, I can still feel the grinding action in my shoulders. I will give it another quick go with the fine paste again tomorrow and then try to start putting some valves back in and seated.

Also, I was playing in the garage and spotted this:

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/th_PC310250_zpsxcjm1lba.mp4

Is not good. Try to ignore the directions given by me to my camera-mum. I don't want to split the cases really, but will if I need to.

Wish me luck!
____________________
Current:1991 Honda MT50 (Soon to be a H100/MTX/MT5 hybrid), 1976 Honda Cub C70, 2005 Honda Varadero 125, 1993 Yamaha TTR250 Open Enduro , 2010 Road Legal Stomp YX140, 1994 Honda CRM 250 MK III, 1999 Cagiva Mito 125, 1992 Honda CB400 Super Four, Stomp T4 230, 1984 Honda H100s, 2009 Sym XS125K
Past:2003 Aprilia RS125, 1982 Kawasaki GPZ550(FREE BIKE!)
I'm having more fun than a well-oiled midget.
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Fladdem
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PostPosted: 21:41 - 19 Jan 2015    Post subject: Reply with quote

Finally got around to putting the valves back in the head. There was an old valve spring compressor knocking about in the workshop, worked a treat for putting the collets back in! Thumbs Up

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/DSC_00341_zpsd2d4b306.jpg

It was a bit fiddly pushing the collets in, but the use of a pair of tweezers and a little pick helped line them up correctly.

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/DSC_00351_zpsdbd84343.jpg

I then decided I should replace the little copper washer behind the bolt that holds the decompressor blanking plug in place, no kick-start means no need for a decompressor, hence the pkug. I thought I should do it while there and the washer was leaking a bit of oil.

Shouldn't have touched it. Brick Wall

Stripped the thread out as soon as the bolt came out, all the old thread was intertwined on the bolt.

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/DSC_00361_zpsf7170fca.jpg

The picture doesn't show it very well, but I was heart-broken. I carefully tried to re-tap the thread at work and I could screw the bolt in but not tighten it down. So I smothered the bolt in Loctite and tightened it as far as it would go and have left it over night with a g-clamp holding it. Laughing I'll leak test it in the morning with some brake cleaner or something thin and see if it works, if not, I'll get the bolt out and try to find a heli-coil to put in there instead. Hopefully it holds and I can bring my head home and begin re-assembly soon. Thumbs Up
____________________
Current:1991 Honda MT50 (Soon to be a H100/MTX/MT5 hybrid), 1976 Honda Cub C70, 2005 Honda Varadero 125, 1993 Yamaha TTR250 Open Enduro , 2010 Road Legal Stomp YX140, 1994 Honda CRM 250 MK III, 1999 Cagiva Mito 125, 1992 Honda CB400 Super Four, Stomp T4 230, 1984 Honda H100s, 2009 Sym XS125K
Past:2003 Aprilia RS125, 1982 Kawasaki GPZ550(FREE BIKE!)
I'm having more fun than a well-oiled midget.
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Fladdem
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PostPosted: 21:05 - 21 Jan 2015    Post subject: Reply with quote

Good news! The Loctited bolt isn't leaking brake cleaner through it when left! Will have to wait now to get the engine running again, with some hot oil under pressure to see if it leaks.

That is all.
____________________
Current:1991 Honda MT50 (Soon to be a H100/MTX/MT5 hybrid), 1976 Honda Cub C70, 2005 Honda Varadero 125, 1993 Yamaha TTR250 Open Enduro , 2010 Road Legal Stomp YX140, 1994 Honda CRM 250 MK III, 1999 Cagiva Mito 125, 1992 Honda CB400 Super Four, Stomp T4 230, 1984 Honda H100s, 2009 Sym XS125K
Past:2003 Aprilia RS125, 1982 Kawasaki GPZ550(FREE BIKE!)
I'm having more fun than a well-oiled midget.
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garth
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PostPosted: 09:26 - 22 Jan 2015    Post subject: Reply with quote

G clamp with a cut out socket to fit the collets. Blob of grease on a scribe to hold them.

I've got some cb-1 wheels here going cheap if you wanted sm wheels. They take 110 and 140/150 tyres, single disc up front.
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Fladdem
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PostPosted: 20:20 - 22 Jan 2015    Post subject: Reply with quote

garth wrote:
G clamp with a cut out socket to fit the collets. Blob of grease on a scribe to hold them.

I've got some cb-1 wheels here going cheap if you wanted sm wheels. They take 110 and 140/150 tyres, single disc up front.


That's a good idea with the socket, I'll bear it in mind for the future.

That's a great offer, but I believe the axle sizes are different to mine, 15mm front, 20mm rear, and I don't really want to make sleeves for the bearings although if I can get custom bearing in those sizes it might be worth it. I have two sets of wheels for the bike anyway, on with proper knobblies on and the other with some sort of dualsport-y style tyres.

God, how I hate the term "dualsport"
____________________
Current:1991 Honda MT50 (Soon to be a H100/MTX/MT5 hybrid), 1976 Honda Cub C70, 2005 Honda Varadero 125, 1993 Yamaha TTR250 Open Enduro , 2010 Road Legal Stomp YX140, 1994 Honda CRM 250 MK III, 1999 Cagiva Mito 125, 1992 Honda CB400 Super Four, Stomp T4 230, 1984 Honda H100s, 2009 Sym XS125K
Past:2003 Aprilia RS125, 1982 Kawasaki GPZ550(FREE BIKE!)
I'm having more fun than a well-oiled midget.
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Fladdem
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PostPosted: 22:19 - 04 Feb 2015    Post subject: Reply with quote

Had a little fettle in the garage tonight. Nothing serious, just cleaned up the surfaces for the new gaskets and stuck some new piston rings on. I don't normally attempt stuff in the evening, but Shreeve's GS250 project has got me annoyed at myself for taking so long to do stuff by having a go on the odd weekend.

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/P2040301_zpspszs2qal.jpg

The old ones came out relatively easy.

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/P2040302_zps9vp20acr.jpg

New ones in

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/P2040305_zpstfsrkib1.jpg

I was going to put the barrel and head on but the barrel is disgraceful, I'm going to use the parts washer at work tomorrow and clean it up there, I'll try to put the engine back together tomorrow night. Then from there, it should start to progress nicely. Thumbs Up
____________________
Current:1991 Honda MT50 (Soon to be a H100/MTX/MT5 hybrid), 1976 Honda Cub C70, 2005 Honda Varadero 125, 1993 Yamaha TTR250 Open Enduro , 2010 Road Legal Stomp YX140, 1994 Honda CRM 250 MK III, 1999 Cagiva Mito 125, 1992 Honda CB400 Super Four, Stomp T4 230, 1984 Honda H100s, 2009 Sym XS125K
Past:2003 Aprilia RS125, 1982 Kawasaki GPZ550(FREE BIKE!)
I'm having more fun than a well-oiled midget.
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Fladdem
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PostPosted: 19:29 - 14 Feb 2015    Post subject: Reply with quote

Look what I got today! After sending it off at the start of January... I'm now 225 pounds lighter Sick

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/P2140317_zpscvb7b10i.jpg

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/P2140318_zpsfkinqbqe.jpg

At least it will be like a brand new unit.

I am going to replace the swinging arm bearings because there is a bit of play in them, I need to get a load of stuff ordered for this bike to start putting it back together properly. I'm going to clean the swinging arm properly and try to get it looking as nice as possible before putting it back in. Thumbs Up

I got the back wheel out and removed all the brake gubbins and chain.

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/DSC_0040_zpse3amslor.jpg

With a bit of an effort, I got the linkage off the swinging arm.

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/DSC_0041_zpsrloxykgv.jpg

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/DSC_0042_zpsnoedv7vw.jpg

I then tried to get the pivot bolt out of the frame, it was very tight, fortunately I have an old bent pair of MTB handlebars for just such purpose. Stuck them over the end of the ratchet and loosen the nut did!

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/DSC_0044_zpsb0brxozw.jpg

I then started trying to beat the pivot out, I got it to move about an inch, then I got the call to get my shock, hopped in the micra to get it, then got distracted on the way home and did a spot of green laning and stuck a new radio head unit in it, I'd already got bored of only listening to the tiny engine struggle all the time. Laughing

http://i1302.photobucket.com/albums/ag134/Fladdem/11004017_10202570248257707_6795491_n_zpszumc7iyd.jpg
____________________
Current:1991 Honda MT50 (Soon to be a H100/MTX/MT5 hybrid), 1976 Honda Cub C70, 2005 Honda Varadero 125, 1993 Yamaha TTR250 Open Enduro , 2010 Road Legal Stomp YX140, 1994 Honda CRM 250 MK III, 1999 Cagiva Mito 125, 1992 Honda CB400 Super Four, Stomp T4 230, 1984 Honda H100s, 2009 Sym XS125K
Past:2003 Aprilia RS125, 1982 Kawasaki GPZ550(FREE BIKE!)
I'm having more fun than a well-oiled midget.
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Fladdem
World Chat Champion



Joined: 29 Jun 2011
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PostPosted: 21:50 - 17 Feb 2015    Post subject: Reply with quote

Yesterday, I tried to reassemble the engine again.

Barrel and head back on, I used plenty of oil to lube the rings, and because last time I took the engine apart, I still had a leak from the gaskets, I used a smear of liquid gasket to help.

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/P2150319_zps9bodfivh.jpg

Cams on, timing set up

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/P2150320_zpswtxvw5dl.jpg

But then of course, I have somehow got all the buckets mixed up, despite making a diagram of the engine, labelling them up and trying my very hardest to keep them from getting mixed up. As such, all the valve clearances are miles out, I spent a good while messing about with the shims in various positions, but I can now no longer be bothered and will probably just get some new shims.

I have another theory that somehow, I got the springs back on the wrong valves and they have all worn slightly different and have changed the clearances.

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/P2150321_zps784jdu3n.jpg

Guess what I battered out of the frame!

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/P2160322_zpsefbdd29j.jpg

That's right, the swinging arm!

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/P2160323_zpsod8kad09.jpg

So, I'll replace those bearings, give it a good cleanup, I started doing half but got bored. Laughing

The chain slider is pretty bad, luckily, it hasn't worn all the way through and started damaging the swinging arm, as far as I can tell. I've got a new one of them as well.

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/P2160324_zpsenrpkpsr.jpg

Hopefully, funding allowing, I should have abunch of stuff turn up to throw on to the bike, the MOT ran out on the 15th and the tax runs out this month, I miss her but don't want to just chuck it back together as quickly as possible because I'll know I'll just be disappointed with myself.
____________________
Current:1991 Honda MT50 (Soon to be a H100/MTX/MT5 hybrid), 1976 Honda Cub C70, 2005 Honda Varadero 125, 1993 Yamaha TTR250 Open Enduro , 2010 Road Legal Stomp YX140, 1994 Honda CRM 250 MK III, 1999 Cagiva Mito 125, 1992 Honda CB400 Super Four, Stomp T4 230, 1984 Honda H100s, 2009 Sym XS125K
Past:2003 Aprilia RS125, 1982 Kawasaki GPZ550(FREE BIKE!)
I'm having more fun than a well-oiled midget.
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Fladdem
World Chat Champion



Joined: 29 Jun 2011
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PostPosted: 22:16 - 19 Mar 2015    Post subject: Reply with quote

Fladdem wrote:
Hopefully, funding allowing, I should have abunch of stuff turn up to throw on to the bike, the MOT ran out on the 15th and the tax runs out this month, I miss her but don't want to just chuck it back together as quickly as possible because I'll know I'll just be disappointed with myself.


Despite saying that, I'm bored now and want another bike, so I'm going to bang it back together and be disappointed in myself. Laughing Another reason is that my girlfriend is coming back to Warwick for Easter in a few weeks and wants to come out on the back of a bike before she goes back to uni, the CRM isn't really very suitable and this I think is closest to being pillion friendly by April. Mr. Green

400 later, a box of stuff turned up! I bought the bike for 1100 two years ago, looking through the paypal accounts, I have coughed up about 1500 in bits so far! Laughing

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/P3180328_zpsdhumvhow.jpg

Finally replaced the indicator lens I lost on the 22nd of September last year.

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/P3180330_zpsvgy9duns.jpg

I also managed to get the valve clearances sorted out, by just buying new shims, I couldn't be bothered to sort out which shim came out of which bucket and where each one went, so I'm glad I got that sorted, blobbed liquid gasket around the new cam chain tensioner gasket and a smear around the rocker cover, hopefully I shouldn't be leaking from there for a while. Thumbs Up

I'm going to tackle the clutch tomorrow, got the new clutch plates soaking overnight. I'm not sure if it's necessary to leave them for so long, but it can't hut the clutch? Rolling Eyes

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/P3190331_zpsreaopiwu.jpg

Old plates

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/P3190332_zpshsxavfnh.jpg

It's a shame the old clutch had a lot of meat left on the plates, but they were just burnt quite badly and it slipped every time I went hard on the throttle.
____________________
Current:1991 Honda MT50 (Soon to be a H100/MTX/MT5 hybrid), 1976 Honda Cub C70, 2005 Honda Varadero 125, 1993 Yamaha TTR250 Open Enduro , 2010 Road Legal Stomp YX140, 1994 Honda CRM 250 MK III, 1999 Cagiva Mito 125, 1992 Honda CB400 Super Four, Stomp T4 230, 1984 Honda H100s, 2009 Sym XS125K
Past:2003 Aprilia RS125, 1982 Kawasaki GPZ550(FREE BIKE!)
I'm having more fun than a well-oiled midget.
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Fladdem
World Chat Champion



Joined: 29 Jun 2011
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PostPosted: 20:36 - 21 Mar 2015    Post subject: Reply with quote

Got the new clutch in last night:

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/P3200333_zpsmbk5gpzm.jpg

I did torque the bolts done to 10NM as recommended by Mr. Yamaha and didn't leave it like that.

I also built up the rest of the engine, I have installed the oil feed pipe, a reconditioned unit, compared to my old cracked one, with new copper washers. I only wanted 6 washers but halfrauds only sold the ones I needed in a multi-pack of 75 Laughing Reinstalled the 'leccy starter motor. Just need to put the exhaust, carb, and airbox on and fill it with oil and see if she runs Twisted Evil

I then lost my marbles and cleaned up the clutch cover, I went from 120 to 1600 grit paper then wire wool and autosol and then a rag and some autosol. It looks quite good. and took me about an hour and a half Embarassed

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/P3210337_zps6kzvnfoa.jpg

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/P3210336_zpsz5xo0kp0.jpg

Swinging arm cleaned up OK, will have a go at replacing the bearings either tonight or tomorrow morning, then give it a quick lick of polish to see what happens.

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/P3210338_zpswdq5en0x.jpg

The cap that sits over the end of the swing arm has been chewed through by the chain

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/P3210339_zps7ckajn6o.jpg

So I had ordered a new one

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/P3210340_zpsl55vpcyh.jpg

Keep watching! Thumbs Up
____________________
Current:1991 Honda MT50 (Soon to be a H100/MTX/MT5 hybrid), 1976 Honda Cub C70, 2005 Honda Varadero 125, 1993 Yamaha TTR250 Open Enduro , 2010 Road Legal Stomp YX140, 1994 Honda CRM 250 MK III, 1999 Cagiva Mito 125, 1992 Honda CB400 Super Four, Stomp T4 230, 1984 Honda H100s, 2009 Sym XS125K
Past:2003 Aprilia RS125, 1982 Kawasaki GPZ550(FREE BIKE!)
I'm having more fun than a well-oiled midget.
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Fladdem
World Chat Champion



Joined: 29 Jun 2011
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PostPosted: 23:58 - 21 Mar 2015    Post subject: Reply with quote

Damn it! My thousandth post is a boring one about replacing bearings. Laughing

I attacked the swinging arm tonight, regardless.

New kit:

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/P3210341_zpswdpvszwq.jpg

The inner shaft just pushed straight out, I love having that grease nipple on the swing arm, it means everything stays greased regularly, meaning it all comes apart easily when it needs it.

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/P3210342_zps6aojjhkq.jpg

The old bearing drifted out quite easily with an old tube of steel knocking about in the garage

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/P3210343_zpsgqnmunmr.jpg

All the old gubbins.

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/P3210344_zpsgemiizdv.jpg

Back in and torqued up

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/P3220345_zpsxwaw2pm1.jpg

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/P3220346_zpscjfdrtsq.jpg

Despite reminding myself constantly, I managed to forget to put the new chain slider on the swing arm before fitting to the frame. Fortunately, if you pivot the arm up you can just slide it over the end and bolt to the arm.

I'm pleased with my efforts so far. I'm not sure what the next logical step would be once I get the shock back in, which hopefully won't take too long. Starting to feel like it's almost ready to go. I need to come up with a way of getting all the scratches and scuffs out of the plastics. I may get a new front mudguard but the rest of it, I am not paying that sort of money to get new panels. Sick
____________________
Current:1991 Honda MT50 (Soon to be a H100/MTX/MT5 hybrid), 1976 Honda Cub C70, 2005 Honda Varadero 125, 1993 Yamaha TTR250 Open Enduro , 2010 Road Legal Stomp YX140, 1994 Honda CRM 250 MK III, 1999 Cagiva Mito 125, 1992 Honda CB400 Super Four, Stomp T4 230, 1984 Honda H100s, 2009 Sym XS125K
Past:2003 Aprilia RS125, 1982 Kawasaki GPZ550(FREE BIKE!)
I'm having more fun than a well-oiled midget.
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Fladdem
World Chat Champion



Joined: 29 Jun 2011
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PostPosted: 21:30 - 22 Mar 2015    Post subject: Reply with quote

Didn't do much today, I had a go at spraying some stuff that was looking a bit worse for wear.

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/P3220347_zpsybunnyzc.jpg

My new exhaust header with freshly painted heat shield, it's quite a good match for the wheels. Laughing I doubt it will last long though with the heat

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/P3220349_zpsztju9h3e.jpg

Sprayed the pillion pegs matte black

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/P3220357_zpswuoianbx.jpg

And the front brake hose clamp

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/P3220356_zpsl1lxrqwu.jpg

And the side stand

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/P3220358_zpsbhot6z6l.jpg

A problem occurred, however, when I went to install the header pipe. I started to tighten the nut down, and somehow, the thread was all stripped out inside the head.

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/P3220352_zpshwwbwwzd.jpg

As an experimental cure, I have cleaned the hole out with my tap and die set, smothered the stud in liquid gasket and tightened it down as much as I could risk it. We'll see if it holds tomorrow night when I try to put the exhaust on again.
____________________
Current:1991 Honda MT50 (Soon to be a H100/MTX/MT5 hybrid), 1976 Honda Cub C70, 2005 Honda Varadero 125, 1993 Yamaha TTR250 Open Enduro , 2010 Road Legal Stomp YX140, 1994 Honda CRM 250 MK III, 1999 Cagiva Mito 125, 1992 Honda CB400 Super Four, Stomp T4 230, 1984 Honda H100s, 2009 Sym XS125K
Past:2003 Aprilia RS125, 1982 Kawasaki GPZ550(FREE BIKE!)
I'm having more fun than a well-oiled midget.
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Fladdem
World Chat Champion



Joined: 29 Jun 2011
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PostPosted: 23:02 - 24 Mar 2015    Post subject: Reply with quote

Not a lot achieved tonight, stuck my back brake back on

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/P3250360_zps0jcho1cb.jpg

I will replace the brake line at some point. I've got nice new braided lines to fit. Very Happy

Got the carb back on.

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/P3250361_zps1rwo8feq.jpg

I put the side stand back on, and re-routed some cables and wiring in the correct manner and replaced some snapped bolts.

I did, however, come across my first of many unidentifiable thing without a clue as to where it belongs. I'm just praying it is nothing to do with anything inside the engine. I'm hoping it was just knocking about on the garage floor and has accidentally found its way into the box of bits.

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/P3250362_zpskxm8fqnj.jpg
____________________
Current:1991 Honda MT50 (Soon to be a H100/MTX/MT5 hybrid), 1976 Honda Cub C70, 2005 Honda Varadero 125, 1993 Yamaha TTR250 Open Enduro , 2010 Road Legal Stomp YX140, 1994 Honda CRM 250 MK III, 1999 Cagiva Mito 125, 1992 Honda CB400 Super Four, Stomp T4 230, 1984 Honda H100s, 2009 Sym XS125K
Past:2003 Aprilia RS125, 1982 Kawasaki GPZ550(FREE BIKE!)
I'm having more fun than a well-oiled midget.
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Fladdem
World Chat Champion



Joined: 29 Jun 2011
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PostPosted: 22:44 - 30 Mar 2015    Post subject: Reply with quote

It must have been a productive evening, I skinned my knuckles. Laughing

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/P3300370_zps8smeljs7.jpg

Set to work replacing the bearings in the top of the shock with a polyurethane bush.

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/P3300364_zps4fieix8v.jpg

Battered out the collars.

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/P3300365_zps6yngyikm.jpg

I drilled a bit out of the eyelet to let me get a pick in to get the circlips out.

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/P3300367_zpsci1muw1z.jpg

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/P3300366_zpsy3odllen.jpg

Battered out the bearing with a socket.

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/P3300368_zpsmx1q1wxg.jpg

I needed to spread the mounting tabs apart to fit the slightly wider bush into the frame.

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/P3300369_zps6qziuilz.jpg

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/P3300371_zpsewretyso.jpg

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/P3300373_zpsm2r7oow5.jpg

Got it in, was a bit of a squeeze.

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/P3300375_zps7udskoyx.jpg

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/P3300374_zpsmwddoawz.jpg

I then put the airbox, battery box, and subframe back on. Next job tomorrow, is the silencer, rear wheel and then get the new chain down to the correct length. I'll then take it for MOT and swap the brake lines over to the new braided ones afterwards. I'm weighing up new graphics as well, but not sure? I need to charge the battery up and then check there is oil pressure.

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/P3300376_zpsbnnqoops.jpg

I didn't want to chuck it together quickly, but the girlfriend has never been out on the back of a bike before and said she wanted to before she went back to uni. There's nothing quite like the prospect of a happy girlfriend to bang a bike back together as quick as possible. Laughing
____________________
Current:1991 Honda MT50 (Soon to be a H100/MTX/MT5 hybrid), 1976 Honda Cub C70, 2005 Honda Varadero 125, 1993 Yamaha TTR250 Open Enduro , 2010 Road Legal Stomp YX140, 1994 Honda CRM 250 MK III, 1999 Cagiva Mito 125, 1992 Honda CB400 Super Four, Stomp T4 230, 1984 Honda H100s, 2009 Sym XS125K
Past:2003 Aprilia RS125, 1982 Kawasaki GPZ550(FREE BIKE!)
I'm having more fun than a well-oiled midget.
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b422063
Crazy Courier



Joined: 14 Oct 2014
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PostPosted: 08:16 - 31 Mar 2015    Post subject: Reply with quote

Fladdem wrote:
It must have been a productive evening, I skinned my knuckles. Laughing

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/P3300370_zps8smeljs7.jpg


Of all the nasty shit I've seen thanks to BCF, including and not limited to people falling off buildings, hit by trains, electrocuted by overhead power cables, this made me cringe the most. I can almost feel your pain.
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Fladdem
World Chat Champion



Joined: 29 Jun 2011
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PostPosted: 22:44 - 01 Apr 2015    Post subject: Reply with quote

I got her built up today. Thumbs Up Twisted Evil

New chain, I'm trying 14/48 sprockets now, instead of 14/52, I want to see if it's nicer on the road but I don't want to lose out too much on acceleration.

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/P4010377_zpsydvonlsd.jpg

Yes, chain is a bit tight.

Time to fire her up!

http://i1302.photobucket.com/albums/ag134/Fladdem/Project%20TTaRt%20up/P4010378_zpsynoox1hd.jpg

https://www.youtube.com/watch?v=X8Gj2504Lv4&feature=youtu.be

The only issue is that after running her up, after about 30 seconds, the header was starting to glow. It seems fine to me, listening to the engine, but I've never noticed the exhaust glowing before now. I wonder if it's the new header, combined with the ported/polished head and I'm not sure if an iridium plug would have an effect? Confused Would the fresh rings cause it to run a bit hot too?

I may richen it up on the needle and see what happens. I might take it for a quick spin around the block tomorrow night and then check the plugs. Any tips on running it in? Last time I was in there I just rode it as I intended to ride it, I just avoided lugging up hills and massive over-revving.
____________________
Current:1991 Honda MT50 (Soon to be a H100/MTX/MT5 hybrid), 1976 Honda Cub C70, 2005 Honda Varadero 125, 1993 Yamaha TTR250 Open Enduro , 2010 Road Legal Stomp YX140, 1994 Honda CRM 250 MK III, 1999 Cagiva Mito 125, 1992 Honda CB400 Super Four, Stomp T4 230, 1984 Honda H100s, 2009 Sym XS125K
Past:2003 Aprilia RS125, 1982 Kawasaki GPZ550(FREE BIKE!)
I'm having more fun than a well-oiled midget.
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b422063
Crazy Courier



Joined: 14 Oct 2014
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PostPosted: 07:35 - 02 Apr 2015    Post subject: Reply with quote

Fladdem wrote:
Any tips on running it in?


This vs. standard wisdom is about to break out.
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