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2003 R1 5PW Rebuild (Pic heavy)

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tom_e
Brolly Dolly



Joined: 27 Feb 2016
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PostPosted: 13:26 - 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: 17:10 - 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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PostPosted: 11:45 - 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

https://i1073.photobucket.com/albums/w384/Rhencullen5/R1%20Engine%20Rebuild/Picture114.jpg
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Nope.
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PostPosted: 21:31 - 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: 23:35 - 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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PostPosted: 02:07 - 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: 23:33 - 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:

https://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! https://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: 10:28 - 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: 11:12 - 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: 00:55 - 12 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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PostPosted: 20:50 - 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:

https://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! https://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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PostPosted: 22:57 - 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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Nope.
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PostPosted: 22:35 - 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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PostPosted: 23:23 - 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: 21:22 - 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: 17:09 - 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: 22:24 - 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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Old Thread Alert!

There is a gap of 3 years, 277 days between these two posts...

Nope.
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Joined: 17 Feb 2011
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PostPosted: 01:07 - 23 Mar 2021    Post subject: Reply with quote

So, it's been 3 years, 9 months, 4 days since the last update. What can I say, I've been busy! Mostly rescuing old computers from Europe (https://ibms360.co.uk/) amongst other things...

Nothing has really happened with the bike. I moved it up to my workshop in late 2019 and thats mostly where its sat since. I've acquired a few parts for it here and there like a clean, undented tank and some gaskets etc. but thats about it.

I went up to the workshop this evening and pulled it out of the back. I made a list of parts I need to move it along, things like rubber grommets for the radiator mounts etc. and I also had a rummage through the garage for some of the parts I was missing (like 3 of the inlet rubbers, which were on the old cylinder head), and put them to one side. I couldn't find the rubber heat shield from the top of the engine or the two plastic covers, so I ordered them from a breaker on eBay today.

Heres how she sits now:

https://www.bikechatforums.com/files/img_1806.jpg

Hopefully I'll get some work done on her soon, and maybe 2021 will be the year I get this (now almost classic status!) R1 back on the road!
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jeffyjeff
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PostPosted: 06:35 - 23 Mar 2021    Post subject: Reply with quote

Impressed by your photographic documentation of this project. It takes a measure of discipline to keep a project logged the way you have. Nice job. Hope that 2021 is the year that your bike hits the road.
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Nope.
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PostPosted: 12:38 - 23 Mar 2021    Post subject: Reply with quote

jeffyjeff wrote:
Impressed by your photographic documentation of this project. It takes a measure of discipline to keep a project logged the way you have. Nice job. Hope that 2021 is the year that your bike hits the road.


Thanks! Fingers crossed this is indeed the year that it gets back on the road looking all nice and shiny! Very Happy
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Nope.
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PostPosted: 23:18 - 23 Mar 2021    Post subject: Reply with quote

So this is where the 3 inlet rubbers were sitting:

https://live.staticflickr.com/65535/51066457613_d432167745_c.jpg

and this is the radiator bottom mount bracket that I couldn't find (and is labeled as an air pump bracket on the parts diagram):

https://live.staticflickr.com/65535/51066457553_fabca89ded_c.jpg

I went up to the workshop tonight and installed the inlet rubbers onto the engine:

https://live.staticflickr.com/65535/51067258327_84b20f40c2_c.jpg

Installed the radiator bracket and test fitted the radiator:

https://live.staticflickr.com/65535/51067258247_7467d492a0_c.jpg

https://live.staticflickr.com/65535/50997974715_e84a90a299_c.jpg

https://live.staticflickr.com/65535/51066457373_0e0da3e9d7_c.jpg

all looked pretty good! I then removed the radiator and put it aside.

Then I dug out the top plastic piece that fits to the frame above the radiator:

https://live.staticflickr.com/65535/50997974575_e22aecd007_c.jpg

https://live.staticflickr.com/65535/51066457248_5004dc7a71_c.jpg

Then I fitted the rubber sheet to the top of the engine and installed the stick coil packs:

https://live.staticflickr.com/65535/51066457163_df033830b9_c.jpg

at this point I wanted to fit the throttle bodies into the inlet rubbers but it was quite cold outside and the rubber wasn't very pliable. I didn't have a hair dryer or a heat gun up at the workshop so I couldn't warm them up so I put the throttle bodies to one side again.

I then found the radiator guard and installed that on the radiator:

https://live.staticflickr.com/65535/51067257812_9bd8f88841_c.jpg

That was pretty much it tonight! Tomorrow I'll install the throttle bodies and connect up the wiring. I'll probably also finish plumbing up the cooling system.

Jobs left to do before I can test fire it with some easy start are:

- Fit throttle bodies
- Plumb up cooling system
- Connect all the wiring
- Oil soak clutch plates and install
- Install Barnett clutch spring conversion
- Fit oil filter
- Fill with running in oil
- Fit left hand rearset to ensure box is in neutral

Then I can spray some easy start down the TB's and see if it fires! If it does then I can fit the airbox, fuel lines, pump into the tank, connect it up, fit the throttle cables and see if it runs properly! Very Happy
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Nope.
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PostPosted: 23:51 - 24 Mar 2021    Post subject: Reply with quote

So, popped back to the workshop today to get a bit more done!

First thing, I wanted to deal with the wiring loom. There used to be tie down points on the inside of the frame, but they were made of rubber and had to be removed for the powder coating. I didn't want to leave the wiring loom just floating around to rub on things so I thought I'd feed a cable tie down through the holes. Easy, right? Well it would seem not. The rubber fixing points are actually attached to large rubber blocks inside the frame. I had to use a small craft knife to cut enough of a pathway to feed the cable tie through, and then I closed the loop and attached another cable tie to affix the loom to the frame:

https://live.staticflickr.com/65535/51069666872_0d24395aaf_c.jpg

The problem I'd had yesterday seating the throttle bodies was mainly due to the inlet rubbers being quite cold in the workshop, and them having been off of the bike for so long. I whipped out the heat gun and warmed up the rubber boots until they were more pliable:

https://live.staticflickr.com/65535/51069666802_7bbbb96641_c.jpg

And then with a lot of wiggling and some percussive persuasion I got the throttle bodies fitted and the clamps tightened up:

https://live.staticflickr.com/65535/51069570781_136b2c6d7c_c.jpg

https://live.staticflickr.com/65535/51068870268_bc3b092ab6_c.jpg

https://live.staticflickr.com/65535/51000385845_19f27ae566_c.jpg

I was going to sort out the rest of the wiring connections, but I got hungry and went home Laughing .

I've also dug out the clutch plates, so once the throttle bodies and connected up, the coolant hoses are run, and the throttle cables are affixed I'll slap the clutch in. I also ordered the first running in oil and a filter today so she's getting closer!
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2011 XT660Z Ténéré - 2003 YZR-R1 5PW (In Build)
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Nope.
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Joined: 17 Feb 2011
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PostPosted: 00:18 - 30 Mar 2021    Post subject: Reply with quote

Sorry this is so bitty, I'm just doing an hour or two an evening when I get a chance. Anyway, onto the next update!

Got back up to the workshop this evening, decided I'd fit the clutch. The clutch pull rod in the casing on this engine didn't have the lever attached to the bottom, so I salvaged the whole rod out of the old casing and fitted that. I then had to torque up the clutch hub nut. The nut is 30mm but my only 30mm socket is 3/4" drive, and my torque wrench is 1/2" drive. Happily one of my friends was up in his workshop and he had a 1/2" drive 30mm socket. I locked the clutch with the special R1 clutch locking tool I bought a few years ago and torqued up the nut to spec.

Then I set about soaking the new Barnett carbon clutch plates in fresh oil:

https://live.staticflickr.com/65535/51082655437_44b0e9e297_c.jpg

and then I started installing them:

https://live.staticflickr.com/65535/51013376975_b4649fed0b_c.jpg

and fitted the Barnett spring clutch conversion plate:

https://live.staticflickr.com/65535/51082655332_03aa86b85d_c.jpg

https://live.staticflickr.com/65535/51082563096_eb28754468_c.jpg

Then I fitted a fresh gasket and put the casing on:

https://live.staticflickr.com/65535/50997640779_c7a836cb64_c.jpg

Fitted an oil filter:

https://live.staticflickr.com/65535/51013376745_1da0f3104d_c.jpg

Filled the engine with 3L of oil and fitted the oil cap!

https://live.staticflickr.com/65535/51081866868_ceb1261c21_c.jpg

It's starting to look more like a bike day by day (excuse the state of the workshop, I'm currently trying to sort it all out and tidy up, but its been made a lot messier in the process!). Bonus points for anybody who can guess what car is in the background...

https://live.staticflickr.com/65535/51082562761_11eb3dc7d1_c.jpg

PS: If anybody knows what the TPS sensor on the side of the TB's plugs into I will be forever grateful. I can't find a connector for it anywhere for some reason...
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2011 XT660Z Ténéré - 2003 YZR-R1 5PW (In Build)
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Nope.
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PostPosted: 23:02 - 05 Apr 2021    Post subject: Reply with quote

I was planning to spend this whole bank holiday weekend working on the bike, however when I got up to the workshop on Friday I just couldn't deal with the mess anymore, so I decided to tidy up a bit. My father kindly agreed to help, and so we pulled everything out of the garages, sorted out what was scrap and rubbish, built some shelves, and put the rest of it back inside:

https://live.staticflickr.com/65535/51097944648_6a1d278ef5_c.jpg

https://live.staticflickr.com/65535/51097484609_cebf01ce20_c.jpg

I had some LED light panels meant for drop ceilings kicking around, so I make some L brackets and put them on the ceiling:

https://live.staticflickr.com/65535/51097500002_40d9a08d2c_c.jpg

Then today I turned my attention back to the bike. I'd contacted Harris and asked to buy some new bolts for the rearsets, which they duly shipped me, but neglected to charge me for! Very kind of them indeed. So I started assembling the righthand side:

https://live.staticflickr.com/65535/51098207635_45ed934a91_c.jpg

https://live.staticflickr.com/65535/51097944888_8c8d58358f_c.jpg

https://live.staticflickr.com/65535/51097484819_5ca889e30c_c.jpg

https://live.staticflickr.com/65535/51097484899_f453663bde_c.jpg

You may notice the brake pedal is missing. Earlier in this thread I removed it to machine a new one, however I lost it somewhere along the way! I've ordered a new one from Harris which will hopefully arrive this week coming.

I then turned my attention to the gear selector. I taped it onto the splined shaft, put the bolt in, and tightened it up. I can now select 1st, neutral, and 2nd with ease!

https://live.staticflickr.com/65535/51097500262_6974f64cf9_c.jpg

Next I decided to fit the throttle cables. This was an absolute mare of a job. I really should have fitted these before I fitted the throttle bodies, but I didn't ,and given what a PITA the throttle bodies were to fit last time, I didn't really want to pull them off again. As such, I went in with a small pair of needle nose pliers and hands contorted into tiny places and managed to get the cables fitted:

https://live.staticflickr.com/65535/51097945268_b439b4f6d6_c.jpg

https://live.staticflickr.com/65535/51097944538_f4fdee5d01_c.jpg

Once I'd gotten it all fitted, the throttle was very sticky. It wouldn't return to idle position without manually turning it, so I stripped the throttle tube down, cleaned the clip on, lightly lubricated it, and refitted the throttle tube. This solved the problem and the throttle now works perfectly!

When I'd originally fitted the exhaust I'd done it with nuts that weren't the perfect thread pitch. I ordered some new ones from Yamaha and changed them all out today:

https://live.staticflickr.com/65535/51098207565_6de6d266d9_c.jpg[/url]

And then I decided to pack up and go home for dinner. This is how the bike sits now:

https://live.staticflickr.com/65535/51097485064_f5dec8c205_c.jpg

I'm hoping to finish the wiring and test fire it later this week if I get the time, but we'll see what the week brings!
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2011 XT660Z Ténéré - 2003 YZR-R1 5PW (In Build)
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Nope.
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PostPosted: 00:13 - 07 Apr 2021    Post subject: Reply with quote

I don't know if anybody is reading this, but its working as a personal log of the work I'm doing at least Laughing .

Anyway, today I went up to the workshop again and thought I'd get the clutch cable fitted. I needed the cable retaining bracket that wasn't attached to this engine, so I found it in one of my bags of parts and cleaned it up:

https://live.staticflickr.com/65535/51100162743_7dab27240a_c.jpg

https://live.staticflickr.com/65535/51099702034_74956197f9_c.jpg

and fitted:

https://live.staticflickr.com/65535/51099701704_d773949da1_c.jpg

Then I finished connecting the wiring to the hand controls and ignition, and I installed the plastic covers. I also fixed the wiring issues I'd had before by tracing back the wiring colours in the haynes diagram.

https://live.staticflickr.com/65535/51100427020_663cd5377f_c.jpg

I then decided to plumb in the cooling system, so I fitted the radiator and got that piped up. I also clipped in the clutch cable:

https://live.staticflickr.com/65535/51099702184_85dbbeac0e_c.jpg

https://live.staticflickr.com/65535/51099702244_8d86d680f0_c.jpg

https://live.staticflickr.com/65535/51100426840_1366e4f98c_c.jpg

The only piece of cooling pipe I couldn't plumb in was the T-piece that connects to the thermowax cylinder on the throttle bodies. I couldn't find this in the box of parts, so I presume its in the garage at home. Hopefully I can find it soon!

I then double checked the wiring over:

https://live.staticflickr.com/65535/51099621151_35a122173f_c.jpg

I didn't have the battery with me (it was on the Optimate at home), so I connected up the Noco I had in the car:

https://live.staticflickr.com/65535/51100426665_7928a8e09a_c.jpg

Got some lights on the dash:

https://live.staticflickr.com/65535/51099701594_b2a9fa9080_c.jpg

Sprayed some easy start into the throttle bodies, pulled the clutch in, hit the switch and:

https://www.youtube.com/watch?v=ZbxSLbtX3lY

Boom! She fired. Albeit very briefly, but now at least I know it's not completely dead and I can build the rest without worrying that the electrics are completely shot!
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