Project: Garage Find

[squirrel_hunter]

Similar, but not the same.

I have seen those pipes but they don't really speak to me. The neck the needs re-welding which is putting me off.

[squirrel_hunter]

The oil pump bolt issue has been fixed and so the clutch cover is back on with a set of new cover bolts from Yambits. But I need a few more bolts to finish of the rest of the engine including the water pump cover as I've been and mislaid them. That is very unusual for me so they must be around her somewhere. I haven't been able to activate the clutch from the arm yet, possibly due to the heaver springs, so will have to wait until the cable is on and give it another go so I'm not filling the engine with fluid yet.



Also put the generator cover on. Its a replacement that I cleaned and polished up.



While I was round there I played with the wiring. Connected up the neutral switch and then worked on the generator wiring routing. I would recommend getting the wiring routed with the engine off the bike in future as there is not a lot of room to work. But eventually the generator was connected up to the loom.



I also put some new exhaust studs onto the barrels. Again like the wiring it would probably have been a little easier to have done this with the engine off but at the time I didn't have them. They are just generic replacement studs but of a similar length and the correct pitch.



Now I was in two minds about putting the next bit up yet but I was so pleased I just have to share. Some other bits haven't been going to well so when I saw this I was very happy.



Yep I have some exhausts now. Martin77 of the TZR forum kindly built me a set of chambers and Dennis Trollope Racing provided a pair of TZ250 silencers via eBay. Even nicer than the set of pipes I was originally going to use.



The springs look really trick. I need some new nuts though and due to the thickness of the mounting plate and the studs I'm using a 1mm or 2mm washer just to space it out. Might also use some thread lock on them to be safe.

Martin wanted me to check the clearance at the rear shock linkage as his jig is based on a race bike so they are usually raised at the rear. I'm sticking with the road set up for now.



Left clearance looks good. And the side stand also clears the pipe.



Clearance on the right also looks good.



Have to share this one of the header and first bend as it really does look nice. Its seeing parts like that which makes it worthwhile.



And finally an idea of how it will all look together. Now all I have to do is take them off and paint them with some VHT black. Almost a shame to do that but it will protect them while in use.

Just waiting for Yamaha to send me some carb parts. Sort the engine balance bar out as its giving me problems. Oh and source a set of induction rubbers as so far people cant quite understand what an undamaged set actually look like. I have more than one set here that are only fit for the bin.

[maviczap]

Looking good, getting the wheels in must be satisfying

[garynortheast]

Coming together nicely, and looking really good too.

[JulesW]

This is a great thread! Thanks for sharing the project

[squirrel_hunter]

It has been a little while since there was an update here. I have been doing some little bits in the background but I've mainly been waiting for parts these past few weeks. The Christmas break didn't help and I'm still waiting for some last few bits and discovering more that I need. Anyway to keep the momentum up, here is a little something I've been working on...



The original carbs. I did think of finding a replacement set and using them but felt that it would be worth having a look at what I had.



So I opened them up, with the use of a Dremel to cut a couple of rounded screws off and this is what I found.



The observant among you may think that these carbs are being stripped down in a bath tub. You would be correct. Where else would I do this sort of work?

Anyway, I thought that cleaning them up might be worth a shot as I'd read about ultrasonic cleaning. Trouble is I don't have an ultrasonic cleaner. So after considering buying one, I decided to take the pair of carbs into Rolling Art Motorcycles as they have the unit and fluid. So after the carbs spent a day in the cleaner I had something that I could work with.



So I started off with the needle slide and a replacement needle set.



Oddly enough at the end of the needle replacement I was left with a couple of bits from the kit. Suggestions please...



Another point of interest was the throttle stop screw. It would appear the Yamaha has changed the design. The original is on the right, the new kit on the left. I've decided to go with the new kit as the original was quite rusty, but useable and I was actually surprised was not seized when I removed it.



So anyway here is the main body freshly cleaned up and blasted with the compressor with a new needle valve seat fitted.



After that the float and pin went in and the float height checked. Both carbs float height were within service limits without alteration.



The bowl bottom with a new drain screw, gasket, and screws were fitted to the main body and the slide put into the body.



And the carb was built once the top was put on. I had to cut a new section of pipe as the original was as hard and brittle as one of my Mothers cakes. Steve Lynham Motorcycles supplied the pipe from their miscellaneous box of bits.



Both carbs are now bagged up to keep them fresh while I wait for the intake rubbers.

[squirrel_hunter]

And I almost forgot, I built a new choke assembly.



New plunger kit and cables were installed to the original choke lever and case. Just need to add a little grease for the slide and install them to the carbs once I have them ready to go on the bike.



But until then they are bagged up like the carbs...

[shiftin_gear98]

You sir are a man with patience, and talent. I salute you.
Can't wait to see it when you finish. Wish I was half as good.

[maviczap]

By the time this is finished, the weathers going to be perfect(ish) to get it out on the road

[TamSV]

Proper job being done here.

It's inspiring me to go a bit further with the RGV but that last step from "good runner" to "mint" is an expensive one.