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YR5 Upgrade project

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GT200Fan79
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PostPosted: 12:36 - 02 Dec 2016    Post subject: Reply with quote

Loaded car with stuff.

http://i5.photobucket.com/albums/y164/BLUEX5/BEC91330-19BB-4066-8F4D-37D179120549_zps3bx6nlp0.jpg

Top end for tuning, mild steel bits to blast / coat and wheels to get rebuilt. Going to get the steering lock cut out and the hole plated over, more weight saving. Barrels getting a "fast road" tune to keep some semblance of rideability and reliability, I can define a lot of the engine characteristics with the electronics anyway.
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GT200Fan79
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PostPosted: 17:54 - 15 Jan 2017    Post subject: Reply with quote

Ok so some progress, got the call that my powder coating and top crankcase were ready to pick up -

http://i5.photobucket.com/albums/y164/BLUEX5/961D7757-01E8-4001-9517-877D72D372D1_zpsohui5kvq.jpg~original

http://i5.photobucket.com/albums/y164/BLUEX5/0B048A80-5C09-4CEE-892C-EB53F565BFBD_zpssde1ehju.jpg~original

Lovely results except the swinging arm but thats because it's been painted over rust several times in the past 40+ years and the steel is very pitted around the brace and pivot, still the bits that are most visible are not too bad. I also asked the guy to remove the steering lock and plate over the hole. Impressed is an understatement, it almost looks like it's never had one.

http://i5.photobucket.com/albums/y164/BLUEX5/CF68F106-62CF-405C-B9FB-97E8D7C856D4_zpsrxbvhraw.jpg~original

Fitted HVC Cycle sidestand relocation kit, this lets you use modern style pipes with the stock centre stand. Bit fiddly but seems to do what is says on the tin. Apologies for reusing the sidestand pivot bolt, I haven't been able to source a new one as yet.

http://i5.photobucket.com/albums/y164/BLUEX5/0A09ED2B-E47D-4F89-852C-1A14F2000051_zpswh0xk2oc.jpg~original

http://i5.photobucket.com/albums/y164/BLUEX5/6D7FD61E-E8DD-4700-A179-12B0F4C8981C_zps1n4puwxg.jpg~original

http://i5.photobucket.com/albums/y164/BLUEX5/CF9CB88D-C57E-4895-A03E-D8B5A18C7C16_zpsze6u0wvm.jpg~original

One of my most hated jobs is fitting headrace and swingarm bearings. With this in mind i popped into work this morning and cut some properly sized washers in 3mm stainless to form a little press to install the races into the frame (and also do the swingarm bushes).

http://i5.photobucket.com/albums/y164/BLUEX5/7CAB3F13-38A4-474E-BBA1-6962CF920673_zpsziunoegt.jpg~original

http://i5.photobucket.com/albums/y164/BLUEX5/3FC5041B-9F12-42E4-9467-490D6A7AC719_zpsscn5znbj.jpg~original

I used a bit of M10 stud iron to pull everything together, was still a fiddle but preferably to trying to hammer them in, which I think would end in tears as they are bloody tight, especially the top race. Job jobbed.

http://i5.photobucket.com/albums/y164/BLUEX5/6D8A2973-C374-4995-BBCB-D7E93AA83034_zpsmulsntn7.jpg~original

Still got the lower race that goes on the stem to change which is another hateful job but i've had enough for one day.

Main goals are to get the chassis assembled and having the top case back lets me crack on with getting the engine built, subject to getting time!
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GSXR1100L, GSXR400RKSP, YR5, GT200
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GT200Fan79
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PostPosted: 14:14 - 26 Jan 2017    Post subject: Reply with quote

Quick update, collected wheels from Tony @ AJ's this morning. Never a cheap job but very pleased! Just tuning on the top end to complete and everything is back. Hopefully will make some progress on engine build this weekend.

http://i5.photobucket.com/albums/y164/BLUEX5/89188458-336A-43B1-83C8-6FDA6FD84F2E_zpskkl3zbgq.jpg~original

http://i5.photobucket.com/albums/y164/BLUEX5/29F9C31A-EDAE-4B07-88CA-3DDF1916B594_zpstfpsorlc.jpg~original

http://i5.photobucket.com/albums/y164/BLUEX5/A7D4921C-AD56-4CF0-9FC1-17D8604B03EE_zpso4zoafrp.jpg~original
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hmmmnz
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PostPosted: 15:50 - 26 Jan 2017    Post subject: Reply with quote

looking pretty damn nice,

all shiney and shit, Very Happy
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GT200Fan79
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PostPosted: 22:47 - 28 Jan 2017    Post subject: Reply with quote

More progress, mainly towards getting the engine assembled.

Vito crank installed

http://i5.photobucket.com/albums/y164/BLUEX5/503A8554-83EC-4AA7-8605-99EA311E1B2B_zpsxihttapp.jpg~original

http://i5.photobucket.com/albums/y164/BLUEX5/F4B2BCC7-0F41-47E1-8B62-A8FDD04AE2A7_zpsraevn6hz.jpg~original

Gearbox installed, new bearings and seals throughout (clutch side output shaft bearing was shagged anyway and with the hoped for increase in power it made sense to have everything fresh.

http://i5.photobucket.com/albums/y164/BLUEX5/735D4409-F640-4F42-B1FF-1D50E040B31B_zpsarslyijz.jpg~original

Top case installed with new SS screws and rev counter drive removed and blanked off.

http://i5.photobucket.com/albums/y164/BLUEX5/77B9D974-142C-4279-ABB3-7E99A69BF868_zpsurxj8wlc.jpg~original

http://i5.photobucket.com/albums/y164/BLUEX5/0B1C5ED8-7566-45D8-8FC2-7FF5C7D92936_zps6wybsztk.jpg~original

Primary drive gubbins and clutch back on.

http://i5.photobucket.com/albums/y164/BLUEX5/26EC59F5-1838-437F-9817-8A0E93B2A371_zpsjos2kyzp.jpg~original

Powerdynamo stator on after some battling adding an extra lead into the harness for the neutral light.

http://i5.photobucket.com/albums/y164/BLUEX5/557D44CF-F89D-4B11-9E00-C006B968141D_zpsaxt3anhc.jpg~original

Rotor installed, need to check basic timing once i get the top end back from tuning and installed.

http://i5.photobucket.com/albums/y164/BLUEX5/4F51F51A-270E-4458-B4EC-5C1D414FEC44_zps4w27eyvj.jpg~original

Productive day, managed to just about sort the fuelling on my GSXR1100 as well!
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pepperami
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PostPosted: 12:26 - 29 Jan 2017    Post subject: Reply with quote

This is coming along nicely Thumbs Up
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Suntan Sid
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PostPosted: 13:36 - 29 Jan 2017    Post subject: Reply with quote

AS pepperami says, some top work there!

A quick question regarding the very shiny wheel hubs, (which I assuming have been polished), have they been lacquered and, if not, how do you keep 'em shiny?
I'm assuming elbow grease, patience and Autosol!
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GT200Fan79
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PostPosted: 15:22 - 29 Jan 2017    Post subject: Reply with quote

Suntan Sid wrote:
AS pepperami says, some top work there!

A quick question regarding the very shiny wheel hubs, (which I assuming have been polished), have they been lacquered and, if not, how do you keep 'em shiny?
I'm assuming elbow grease, patience and Autosol!


Nope, natural finish. The bike is going to be for track and summer lulz so I don't intend on riding it in shitty weather. I'll keep on top of it with an oily rag and wipe it with WD40 before storing the bike over winter.
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Suntan Sid
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PostPosted: 17:23 - 29 Jan 2017    Post subject: Reply with quote

Cool, no alloy fur for you then!

I had a few spare hubs when I was doing my resto, I polished one and left it to see what would happen, it dulled after a few weeks in the cellar, so I painted the ones I put on the bike.

Keep up the good work, looking forward to the finished product, nothing better than a good rebuild, especially on a bike that's going to get used, rather than become a museum piece! Thumbs Up
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GT200Fan79
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PostPosted: 12:26 - 25 Feb 2017    Post subject: Reply with quote

Little bit of progress. Picked my top end up from the tuning man this morning. We decided on a "fast road" port map which has been proven and is actually used with some success on a couple of race bikes, should give good power without being too much like a full on TZ.


Opened and razored transfers.

http://i5.photobucket.com/albums/y164/BLUEX5/C5C9A98A-854C-40B6-825F-DA32A4BDFFAE_zps7ukwep4e.jpg~original

Intake port opened out.

http://i5.photobucket.com/albums/y164/BLUEX5/31B6DDDE-C280-4577-9267-5635821703DD_zps0m9tbfo1.jpg~original

http://i5.photobucket.com/albums/y164/BLUEX5/921D8E58-D6E3-4810-9BDD-E68DA9FF40BF_zps1ful9toa.jpg~original

Exhaust port widened but not raised by a silly amount.

http://i5.photobucket.com/albums/y164/BLUEX5/223B3586-E652-4846-AF3B-301558350C99_zpsyirhtdms.jpg~original

By the look of it the heads have been previously fettled. The extra chamfer on the edge of the combustion chamber apparently isn't Mr Yamaha's handywork. Chamber capacity is also spot on at 11.5cc.

http://i5.photobucket.com/albums/y164/BLUEX5/48A4A954-6640-4E54-887A-1A0C3025EC34_zpslwiqzyof.jpg~original

I have a slight issue i hadn't checked with these Indian barrels, one side is tight on the piston so I need to really get both measured up and clearances checked and the tight side honed. Then I can set the squish and static timing with the engine out of the frame (much easier!) and the fun begins!
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For speed add lightness. You canít make power without revs.

GSXR1100L, GSXR400RKSP, YR5, GT200
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GT200Fan79
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PostPosted: 20:32 - 05 Mar 2017    Post subject: Reply with quote

Spent a few hours at work today making some of the fiddly bits I need to hand when I start bolting the thing together.

Things like the new battery / electrics box, coil mount etc I want sorted out now so I've been spending alot of time thinking everything through and doing fag packet drawings to work out roughly how to do it.

Anyway I was pretty confident with how i was going to do most of these things so decided to move onto CAD/CAM and get some metal / plastic cut...

http://i5.photobucket.com/albums/y164/BLUEX5/IMG_3341_zpsivksivs6.jpg~original

http://i5.photobucket.com/albums/y164/BLUEX5/IMG_3342_zpsp9k7i8nj.jpg~original

Then fire up water jet -

http://i5.photobucket.com/albums/y164/BLUEX5/IMG_3343_zpsb4matjwe.jpg~original

The purpose of these bits will make more sense when I start recording the assembly process, but basically the round bits are to adapt the remians of the original clock bracket to take the small aftermarket speedo and electronic tacho i intend to use. The nylon part is the lid for the 100mm3 galvanised box which will house the 1.2ah house alarm battery, Zeeltronic ignition and the reg / reg (on the bottom), and the Z shaped lump of stainless will form the battery clamp. Just need a hole saw and some grommets as I want to take the ignition wiring and USB takeoff through the bottom of the box.
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GSXR1100L, GSXR400RKSP, YR5, GT200
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GT200Fan79
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PostPosted: 20:42 - 05 Apr 2017    Post subject: Reply with quote

No real visible progress in a while, mainly been perfecting the battery box arrangment and painting odd bits and bobs. Real impetus now is to get the thing together as a rolling chassis as i'm sick of tripping over the frame and swingarm!

Mudguard is a new (pattern) jobbie, undersealed as my usual practice, chain guard, shocks and indicator rail are the original's attacked with Autosol. Not perfect but shiny enough. The eagle eyed among you will also spot i've junked the hateful UK spec rear light in favour of the much better looking US type.

http://i5.photobucket.com/albums/y164/BLUEX5/9FA246C2-6456-464C-B629-220323A6B681_zpsucxy5eoq.jpg~original

http://i5.photobucket.com/albums/y164/BLUEX5/6B71C385-BCD4-47B5-890E-521A52A49E45_zpsqkfocb4w.jpg~original

The engine is still in limbo, i had intended to O-ring the heads but the plug holes are not in the centreline of the combustion chambers so it wasn't that easy. Currently state of play is that the barrels have been machined flush to eliminate the standard copper ring and use RD400 head gaskets. The squish can then be set by base gaskets or further milling. The plan is to get squish sorted and static timing marks sorted before the engine goes back in the frame.
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GT200Fan79
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PostPosted: 14:13 - 08 Apr 2017    Post subject: Reply with quote

Finally a rolling chassis of sorts, kitchen reclaimed!

http://i5.photobucket.com/albums/y164/BLUEX5/01FA666D-08B9-41E1-A538-9F5730539EC7_zpsluteef6q.jpg~original

http://i5.photobucket.com/albums/y164/BLUEX5/E13BA688-1AA1-434F-B3A0-65028AA84F07_zpsliottxf8.jpg~original

I need to take the forks back out and install the reflector brackets under the headlight "ears" as there is too much slop without them (was hoping to junk them and save some more weight). Also realised i didn't have a bolt for the front of the rear torque arm so waiting on one of those, bit frustrating.
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GT200Fan79
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PostPosted: 16:44 - 17 Apr 2017    Post subject: Reply with quote

Frustation setting it with bits all over the place so I've been making a concerted effort to get parts bolted onto the rolling chassis.

Renthal flatties and controls back on including what will be the map switch once I get the wiring sorted.

http://i5.photobucket.com/albums/y164/BLUEX5/9C34A8C2-88C3-4C4C-9646-323339B162B1_zpscsir7hlx.jpg~original

Electrics box painted and contents installed. It holds the Zeeltronic CDI, a 1.2ah gel battery and underneath in the open air is the reg / rec unit for the Powerdynamo unit.

http://i5.photobucket.com/albums/y164/BLUEX5/4E6343C0-B30D-4054-81C8-05E8805D2FA9_zpsfyjqg5fa.jpg~original

http://i5.photobucket.com/albums/y164/BLUEX5/27C01836-80EA-43D0-9C20-AD676B0C280B_zpsou3nitzk.jpg~original

http://i5.photobucket.com/albums/y164/BLUEX5/BBF3E3B2-C944-4C2B-B7C3-5F22C62A8391_zpsnuzqkmtf.jpg~original

Then installed in the frame, located on the original rails where the OEM battery box clips in. Paint took a bit of a battering when I was installing the spacers but I'll touch it up later.

http://i5.photobucket.com/albums/y164/BLUEX5/184172AA-C8A7-4438-A38B-E5D1D97C4148_zpslbhxefwm.jpg~original

http://i5.photobucket.com/albums/y164/BLUEX5/F05B7D74-32FC-4F4E-B004-BD4169564648_zpsm6vry671.jpg~original

Next step is to get the engine back and installed so I can work on the wiring.
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stevo as b4
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PostPosted: 19:43 - 17 Apr 2017    Post subject: Reply with quote

That's one very neat bit of engineering and fabrication to hold all your electrics and a very nicely routed and secured loom too Impressive! Thumbs Up

I soldered on two new battery terminals on my KMX over the weekend, and despite using heat shrink, Ive made a right dogs dinner out of it. Thankfully the Motobatt battery I'm using has multiple options for mounting the terminals.

Have you got much more to do now to get it running for a set up? I can't remember if you went for new carbs in the end or was it TZR carbs you fitted?

I'm still waiting for a new pipe, can't see me being back on the dyno before at least the end of May at this rate?

The next classic bike I rebuild will be completely std, as I might even get some use out of one then?
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GT200Fan79
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PostPosted: 20:48 - 17 Apr 2017    Post subject: Reply with quote

stevo as b4 wrote:
That's one very neat bit of engineering and fabrication to hold all your electrics and a very nicely routed and secured loom too Impressive! Thumbs Up


The box is a standard galvanised electrical box, but i made my own lid and own holes for the loom and access to the USB port. I bought about 3 different sizes to play with before settling on 100mm3. The fit is a bit snug where the loom comes out and bends round but it does just go in against the mudguard!



stevo as b4 wrote:
Have you got much more to do now to get it running for a set up? I can't remember if you went for new carbs in the end or was it TZR carbs you fitted?


The cylinders are with a mate of mine getting worked over (skimmed and modified to use RD400 head gaskets, and piston / bore clearances checked). Once they are sorted we need to assemble the top end, set squish clearances and establish static timing marks. As my mate is just into his first season of YPM racing there isn't a definite time frame on this, but sooner rather than later. Then the engine unit can come back to my shed and go in the frame. There is a quite a bit of wiring to do but once the engine is back an initial start up shouldn't be too far away (famous last words!!!). I'm using brand new VM28 round slides, i wanted to use the TZR carbs but refused to pay £100 plus for old, possible incomplete carbs. I know I have new needles, no distorted or missing bits and no issues matching cables.

stevo as b4 wrote:
The next classic bike I rebuild will be completely std, as I might even get some use out of one then?


My X5 fulfills this role. 80 miles of trouble free pootling and nice manners today!
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GSXR1100L, GSXR400RKSP, YR5, GT200
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GT200Fan79
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PostPosted: 18:11 - 18 Apr 2017    Post subject: Reply with quote

Test fit of the clocks I intend to use.

http://i5.photobucket.com/albums/y164/BLUEX5/85AF02F6-497C-4EF9-A1BB-F8AFE33A055B_zps5zokkjj9.jpg

Look and fit is exactly what I want so I hope the bloody things work!
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pompousporcup...
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PostPosted: 16:35 - 19 Apr 2017    Post subject: Reply with quote

Looks good n shiny!
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Do You Even Lift
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PostPosted: 18:58 - 23 May 2017    Post subject: Reply with quote

take your time dan...
Sleeping Sleeping Sleeping Sleeping
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GT200Fan79
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PostPosted: 13:59 - 27 May 2017    Post subject: Reply with quote

No progress in a while, the barrels were away getting honed to the right clearances amongst other stuff. Yesterday we got the top end bolted down and squish measured. It's landed about 1.3mm which is a bit bigger than the 1.0mm I was looking for, but I can alway adjust it be using thinner base gaskets later. Also set up a dial gauge to create timing markers for TDC and the standard firing point (1.8mm BTDC) so I have a reference for strobing once it's running.

Engine back in frame this morning - such a simple task. Bottom mount left out for now as it bolts through the right hand exhaust bracket which will probably need to come off when I sort the rearsets.

http://i5.photobucket.com/albums/y164/BLUEX5/1929FC92-E196-444A-9D26-BA5C0E7CE4B6_zpspis1lk0n.jpg~original

5mm Reed spacers installed in an attempt to widen the powerband. Now glad I went for the sponge filter rather than the K&N as the reed spacers mean the filter element actually rests on the battery box.

http://i5.photobucket.com/albums/y164/BLUEX5/2759251E-56AF-4624-B674-EF3164150D05_zpspedesjur.jpg~original

I hadn't been able to test fit the JL pipes when I bought them last year as the centrestand lugs needed to come off. So this was a priority in case any further work was needed.

http://i5.photobucket.com/albums/y164/BLUEX5/49C95E62-4B03-4A8F-A7A2-128933BEB8F1_zpsjmxiiodp.jpg~original

http://i5.photobucket.com/albums/y164/BLUEX5/B368A850-7B5C-4430-8B3C-BB3CD6F78CFD_zpsw3oamdzm.jpg~original

I hit one major issue - most pics / videos I've seen where people have used these pipes show them bolting to the front of the exhaust brackets. If I tried this there is no way the side stand would go past the chamber, even with the extension mod. So I swore and stamped around a bit, then tried it with the chambers bolted up behing the exhaust bracket. Problem solved, but the silencers do point inwards slightly as a result. After staring at it for an hour I decided it looked ok and gave me another ground clearance improvement.

http://i5.photobucket.com/albums/y164/BLUEX5/5EBBE95D-910A-4EA8-81B0-E5F752E9370C_zps7e2ekcgz.jpg~original

http://i5.photobucket.com/albums/y164/BLUEX5/FB46724B-D3A2-400D-8221-C82069309C88_zpsrwc7qtp6.jpg~original

Other than the stand issue I really like these pipes. They look thoroughly modern and the cylinder barrel mount is good quality.

Next step is to sort the rearsets and start wiring everything up.
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GT200Fan79
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PostPosted: 20:34 - 06 Jun 2017    Post subject: Reply with quote

Redirected my attention to the wiring. I have quite a bit of work ahead with building a new sub loom for the new generator and CDI as well as other functions that Yamaha never thought of at the time (Electronic tacho, shift light, map switch etc). As i'm not using the original generator the standard wiring loom has quite a few surplus circuits. Originally my intention was to just chop off the spurs I didn't need and tape up the loom but my mate said that was a bodge and I needed to cut the loom open and physically remove the surplus wires.

http://i5.photobucket.com/albums/y164/BLUEX5/3D49FF36-2A5C-4B40-8139-A6D35489F258_zpsnxsa1rhm.jpg~original

Using a sharp modelling knife I began removing the 40+ year old loom tape, messy job! I wanted to remove the spurs that went to original generator (except the neutral circuit), original reg / rec unit and also the left and right contact breaker feeds. Actually removing the old tape was the hard bit, once the loom was open a few snips wand the offending wires were consigned to the spares box. I then retaped the area I had cut open and tested all the circuits with a multimeter to make sure i hadn't caused any other issues.

http://i5.photobucket.com/albums/y164/BLUEX5/2E438922-9D17-43FC-91CD-00C05C5EA132_zpsbggs1z6a.jpg~original

Job done! Just the remains of the old tape to hoover up...
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For speed add lightness. You canít make power without revs.

GSXR1100L, GSXR400RKSP, YR5, GT200
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Paddy.
Red Rocket



Joined: 14 Feb 2008
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PostPosted: 17:36 - 07 Jun 2017    Post subject: Reply with quote

Those pipes are fit.

I like the slightly inward facing exhausts mate... This is definitely something I'd like to see finished.
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Current ride : Suzuki GSXR1000 L0 - Suzuki SV650 track bike - Yamaha Majesty YP250
My biking history so far
Rogerborg wrote: Whole life care for a VTR full of quadraspazzed Darrryls and Shoniq'uas cost mad dollah.
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GT200Fan79
World Chat Champion



Joined: 06 Oct 2015
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PostPosted: 20:48 - 07 Jun 2017    Post subject: Reply with quote

Paddy. wrote:
Those pipes are fit.

I like the slightly inward facing exhausts mate... This is definitely something I'd like to see finished.


It'll get there. I spent an hour working out the wiring routing tonight and think i've made some progress, so next job is to start patching in the additional items. Fingers crossed that shortly after we'll have a spark and can think about seeing if it'll run....
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For speed add lightness. You canít make power without revs.

GSXR1100L, GSXR400RKSP, YR5, GT200
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Suntan Sid
World Chat Champion



Joined: 07 May 2009
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PostPosted: 10:55 - 08 Jun 2017    Post subject: Reply with quote

'Tis a thing of beauty already, can't wait to see and hear it, finished, in all its glory! Thumbs Up Karma
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GT200Fan79
World Chat Champion



Joined: 06 Oct 2015
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PostPosted: 15:34 - 08 Jun 2017    Post subject: Reply with quote

Almost forgot to whore my HVC / Fast from the past rearsets.

Utter quality.

http://i5.photobucket.com/albums/y164/BLUEX5/691A4ED8-2979-4E9A-AD39-005B50D9E42E_zpsl2pxtwrd.jpg~original

http://i5.photobucket.com/albums/y164/BLUEX5/6AD05CAF-CD47-4B76-A078-221489CF07DC_zpsjazxjdpx.jpg~original
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GSXR1100L, GSXR400RKSP, YR5, GT200
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The last post was made 2 years, 44 days ago. Instead of replying here, would creating a new thread be more useful?
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