I had assumed never assume! The welds were ground back and all looked good. Before returning to stripping more parts from the bike, I cleaned up some more sub assemblies, including: 1, Cleaning up the 'alloy look'! Gives the paint a look like a 'crackle' finish! This is Factory repair manual and is vehicle specific. With the wheel off the fork legs slipped out nice n easy and before I undid the triple clamp bolts I checked the top caps since I wanted to change the oil at the very least on them, and both tops were loose. One bonus of using a setup to spin the wheel is that you can easily tell if the wheel is buckled or out of alignment with the hub, in the case of both of these wheels, they tracked nice and true, phew! It is fraught with danger, but. This sort of thing is one of the typical problems with a mass produced engine, and as the 250 has smaller transfers so the case parts are less of an issue than with the 350, so of course no one had ever tidied up the ports sizes on these cases. From what i was told all proper engineering companies should do rebores this way, i.
Broken down on the trail or site and have a smart phone? When they arrived I was a bit blown away to be honest! At least the bleed nipple didn't snap off when I undid it. The rest of the parts were all new. Be prepared for it when it happens by simply purchasing this service manual for later use! I opened a lot of yamaha branded packets that day. I also added a bit of the spare clear decal under where the light switch slides in the hope that it wont wear the paint quite as fast. They did have the demon silver rattlecan overspray that the whole bike had suffered, but an hour with a rag and some thinners and then some Armorall and they are back to black again. The whole setup had only done 30km i.
I say that as they will need adjusting to fit as the brackets and the top pipe are out and will need repositioning, just like the early Chinese units. Next job : loading with carbs. Looking at the logos next to each other, it's totally obvious the colours are different reds when you see the decals side by side, but not so obvious in photos. I would need to engineer up some other solution. No shipping fee, No waiting nervously for the postal delivery, you can start doing your repairs right away! Scheduled motorcycle maintenance should occur frequently at regular intervals.
? This allowed me to split up the huge job into 3 manageable tasks with a lot less wires to work out and solder. So, yes I didn't get that order right the first time and did that whole shock-in-shock-out-dance a few times until I had the order right, but that's how you need to do it really. In fact I have now looked at the photo I was basing my extra logo idea on, and its also the 84 colour on the 85 bike. Now the bike looks like some sort of preying mantis when set up like this. Shame it wasn't a rear.
Added a new bleed nipple, a nice new banjo and some compressing washers. Next I decided to build up my rear end with all the nice clean parts. Routine maintenance and periodic repairs at home will save you money and prolong the life of your motorcycle. The one that came with my bike was what must surely be one of the nastiest looking brake calipers ever. It easy enough to redo it later if needed, but I doubt I would have to on sections 1 and 3.
They arrived were quickly fitted. Long story short, too late now I know! What I learnt from this exercise is that the fitting is actually simpler on the faired models as the rad sits well inside the faring and having it a few cm forward and even a little wider wont mean it gets in the way with anything, some good news at least! The toothed belt was shredded of course. Many people buy this manual just to have it around for when the inevitable happens. Dressed the edges of the clutch basket a little and fitted it but could not add the plates as I was waiting for the locking tab, lack of parts can really slow progress. Which took huge effort to pump out. Conventional wisdom suggests that the aftermarket head gaskets are an accident waiting to happen.
It is this level of detail, along with tons of photos and illustrations, that guide the reader through each service and repair procedure. So while the goons at PartsnMore sent me 4 instead of 2 bearings. Did I mention I hate that powdercoater? Time to restore what I have. Original green passivated finish remained mostly intact as well which was nice. Not only with orders from the usual marque specific suppliers but also mundane things like bolts and nuts. So thanks a bunch Parts and More, you wasted my money and worse still, my time. This routine maintenance should include changing the oil, inspecting the shift linkage - steering - suspension - coolant system - fuel system - drive belts - engine mounts, changing the spark plugs, and replacing the fuel and air filters.
So this is what I had: Next job was to fit the rear wheel, but first it needed new bearings in the wheel and carrier and finishing off. The notable exception mentioned earlier. I knocked out the bearing cups on the headstock, which looked original and were amazingly not in bad shape, they were still nice and greasy too. The tie bars were from an old racers stash of parts I bought as mine were quite rusty. With proper care and routine maintenance, your motorcycle will provide many years of reliable use. These would have been a labour of love for sure for whoever did them, either me or the painter, but luckily I would manage to source better ones over time. Withe the engine almost complete I began to think about the frame and once again consider colours.
The top fitting is dimensionally in the center line of thickness of the rad. I noticed that the oil tank was a bit rattly and lo-n-behold inside I found a nozzle from a silicone sealer tube! I decided to drown my sorrows in progress. Building any bike over a more than 2 years period means that it can become a bit of a voyage of discovery at times, like when you rediscover a bunch more parts that have been hidden away. All content copyright Jon Wallis 2009-Present. I should add that I always thought the naff carpet and rugs the last people left in the garage was nasty and really just needed chucking out, but the one in my workshop has been useful to the stop fresh powder getting damaged Stands are on, engine stabilisers and some rubber bungs, but really I was just trying to get to a stage where I could fit the front end and then it could stand up on its own whilst I sourced the last few linkage parts for the rear end. Always nice when that happens.