Winter Project

[coxylaad]

Leave it pink, it's pretty, good work so far, cupla questions though.

 

1. Looks like you left the headstock races in but covered with a big washer both ends, i always assumed they would need to come out for a powdercoat ! guess not.

   I've done it a couple of times now and if you take your time it seems to work ok (so far) I filled the area around the bearing surfaces with silicone, then pressed on a fabricated plate top and bottom with a piece of threaded bar clamping it together. 

its all a bit of a mess when it comes out but other than a bit of tarnishing with the heat the surfaces seem fine. even if I were replacing the bearings I would still do all this as you really dont want your frame bearing surfaces powder coating!

 

2. What did you use to clean up the engine, cos it was really manky looking before hand, must of done a good clean as ya paint has stuck on

Some engine degreaser, a brush, about week of graft. finished off with a blast with that aerosol parts cleaner spray to give it that pristine finish. had no reaction on the paint on the engine anywhere. Cant complain.  The wife can however after I have repeatedly tromped lumps of oil gunk around the house via the bottom of my foot...

 

3. Which paint did you settle on for the engine, looks lubberley :good:

I went to paint suppliers and he recommended a specific brand of BBQ paint that a reputable engine builder uses all the time. seems to have done the job nicely. Lets hope it holds up. 

 

 

You would know all about a pink rim Wicky.

 

What spin cycle do you use after washing the parts coxxxxxxxxxxxxxxxxylaaaad?

 

dont. its still not funny in our house. I had bit of engine degreaser and engine gunk splattered everywhere in the clothes washing area!

 

 

Hows that KTM making out ?

[dandywarhol]

 

dont. its still not funny in our house. I had bit of engine degreaser and engine gunk splattered everywhere in the clothes washing area!

 

 

Hows that KTM making out ?

 

 

Plasticote BBQ/Woodstove perchance?  Good stuff on 70s Jap 2 strokes.

 

It'll be interesting to see what difference the F800 bodies do - I've got the original dyno run files somewhere.

 

Loving Katie 2 - roads a bit salty/greasy but she'll be a keeper! Metzler Sportec RR tyres just spin up when stone cold - I thought I'd hit a false neutral at the lights - then the rear end stepped out 6 inches, then gripped!. It's a hoot...................  :pimp:  

[dablik]

Cheers coxy good info, have heard of bbq paint being used, i would normally belt the races out but that seems like a decent method, cheers :good:

[coxylaad]

Dandy dig those dyno graphs out and let's have a look at them

[coxylaad]

Attempting to keep some momentum with the project I managed to get another hour in the garage last night. 
The floating front engine mounts were old and rotten, so I used them to keep the internal surfaces free from being powder coated and made some more up:
 

 

 

 

 

 
Job done, the engine is now securely mounted, the rest of the rebuild can continue. 
 
I am not particularly keen on the finish of my rocker cover, but to be fair 95% of it will be hidden anyway. I actually have a spare rocker cover that I might get powder coated and anthracite colour. 

This post was last modified: 12-02-2019, 09:49 AM by coxylaad.

[dandywarhol]

I remember reading about these mounts when they first came out - there is a tightening sequence to eliminate vibration.

 

This is the only one I can find for now. If I recall, the blue run is after the Akra end cans were fitted and a weird map was a result of it. Got the map somewhere in the annuls of time and old 'puter

 

No RPM because the clip on lead broke - again from memory, the line around 60 mph is max torque area - a healthy rise there at a very useable part of the power band with the Akras

This post was last modified: 12-02-2019, 10:22 AM by dandywarhol.

[coxylaad]

Thats good info Alan cheers. 

 

I will be interested a) to see what its putting out now all those years on from the engine modifications, and with the addition of the ignijet unit, the new exhaust headers I am going to build for it, then eventually with the larger throttle body setup. 

once its back together I am going to get a day on a rolling road and get it setup properly. 

 

other mods I have in mind are coil over plug sticks instead of the old coil setup. Mainly because its a neater solution and also the ignijet can be programmed for any type of ignition so why not! 

[ramotdm]

coxy I thought about ya project when I saw these

 

https://www.ebay.co.uk/itm/YAMAHA-TDM900...ctupt=true

[coxylaad]

Remap is suggested. 

They work perfect with high compression pistons, after market cam shafts and larger throttle bodies. 

wtf! that sounds like they are describing my bike!

[jbx]

Great job Coxylaaaaaaaaaaaad !  :good:

Amazing transformation of artifacts exhumed from a medieval burial site to nice & shiny metal wonders. 

[coxylaad]

No pictures but I cleaned and refitted the plastic undertray using all new stainless bolts, and I have cleaned up and started to install the wiring loom into the bike. 
its at that point you realise you should have installed the wiring loom before the undertray and you have to take it all back out again   :good:
 
Getting there though. I am putting off cleaning up these throttle bodies, but it will be done this week. 
 
I've decided just ordered a new set of steering head bearings anyway. They look like the originals, and if that's the case they have 97,000 miles on them - which is impressive.

[Matlock]

I've decided just ordered a new set of steering head bearings anyway. They look like the originals, and if that's the case they have 97,000 miles on them - which is impressive.

 

Barely run in    My 900 is on 98,000 miles and on the OEM steering head bearings. I've stripped & greased them a couple of times, but they've never needed replacing. I reckon it's down to regular use :good: . 

[coxylaad]

That is impressive! 

 

I've ordered some new ones anyway. It would irritate me somewhat if I didn't and they failed in 6 month. 

[Studley Ramrod]

A sonic bath would clean them throttle bodies in no time.

[coxylaad]

Maybe but I dont have one

[dablik]

Could always boil em in lemon juice eh

[dandywarhol]

Cillit Bang does a great job  :good:

[coxylaad]

current status. Starting to look like a bike again:
 

 

 

 

 
Theres quite a few jobs I would like to do on the bike, but the weather is getting better so I need it roadworthy asap. I will end up having a 'phase 2' of the restoration/modification. 
 
The biggest job I have left to do is the exhaust. I could refit the standard exhaust, but its really minging. I have a 44mm 2 into 2 system for a TRX850 but the 2 down pipes are the wrong shape and it just wont fit.
Options are:
 
sell it to fund another exhaust system
modify/make new downpipes to mate to this system
fit the old shitty system and just dont look at it.  
 
that system on ebay was interesting, it was a 38mm system to start with the same as stock, and halfway down the down pipes it opened out to 42mm. 
 
another option would be to modify the existing pipes to copy that setup. Shouldnt be too difficult.

This post was last modified: 18-02-2019, 12:13 PM by coxylaad.

[Rallyist]

Bearing lack of grease???

[coxylaad]

at that point yes. I thought it best put the yokes in position before i greased it up so it doesnt get everywhere.