CRUNCH TIME: Motor re-assembly has begun!!!!

[Pork Chop]

no, not the raised part.

If I am going to do this then I really don't want to bugger it up. Is a file or dremel best for the job?

Also, Greasey your cylinders look great - I will give honing a try this weekend and lap the valves too (got the grinding compound today).

 

[Greasey Fingers]

did you buy the little stick with the suction cap on the end? (lapping tool)

 

[Pork Chop]

Nope, repco wanted $19 for it. I will try a wooden spoon with double sided tape or my magnetic bolt finder.

 

[drewpy]

If I am going to do this then I really don't want to bugger it up. Is a file or dremel best for the job?

Also, Greasey your cylinders look great - I will give honing a try this weekend and lap the valves too (got the grinding compound today).

I'd use a hand file, if your not sure just leave it.
Its been there 20 odd years or so.

 

[Greasey Fingers]

Sorry to hijack the hijack but i have progress to report Happy to say we put in a solid session today.

STAGE 4

New oversize pistons installed, piston pins & circlips renewed and of course a fresh set of piston rings all round. All went on nice into the freshly rebored barrels. As mentioned before all the valves have been lapped and new valve stem seals installed. All seals & gaskets replaced as the top end was put back together. All the new shiney bolts were used and look awsome

So in short top end is back together. Next session will be putting the motor back in frame, doing timing/valve clearances, hooking everything up and giving her all we got and hopefully firing her up!!!

 

[Greasey Fingers]

More pics...

 

[Greasey Fingers]

last couple...

 

[Pork Chop]

Nice work.

Did you have any dramas? How did you compress the rings? Did you lubricate the pistons prior to install?

I have been waiting for you to do this before i did mine so i could learn from your mistakes...

 

[Greasey Fingers]

Hey man no worries I do hope this thread is useful in future, its nice to give a little love back to the forum anyway

As for the rings, I was going to use the ring compressor but it just seemed to make it more complicated. We just lowered down the barrels and pinched the top ring together and eased the barrels down. There is like a lip on the start of the sleeves which is tapered and seems to be designed so you just slip the pistons in and the tapered sleeve help feed them in

So anyway no big dramas to report We really took our time and went real methodical. Yes we lubricated the piston pins/pistons/barrels with plenty of oil. Also lubricated the cam and filled the little cam oil reservoirs.

One thing you need to keep in mind is intalling the cam in the correct position. Just read the manual in regards to the little markings on the cam sprocket. Just take your time and read and re read until you are sure you got it right! But yeah its not to bad, trickiest bit imo is correctly installing cam. I have a photo there of the cam in position, which i beleive is correct. If it isnt PLEASE someone tell me!!!

 

[drewpy]

nice, did you offset the ring gaps as per manual?

I always found it easier to use fingers to install the pistons than a compressor. I think the lower bore is tapered anyway!

cam looks good to me, always hand turn the engine to check for any problems. should be done for all engines.

 

[Greasey Fingers]

Hey Drew! I staggered the ring gaps but I didint think the manual specified exactly how? I just made sure no gaps were above each other and were well away from the one beneath...should that be cool?

Yeah I agree fingers is best for compressing the rings to go into the bores, and also for installing them onto the pistons. And yeah the lower bore is tapered to help ease them in, seems to make life a whole lot easier.

We turned the motor over and it turns over nice, no bad sounds to report feels great so far.

 

[drewpy]

so long as they are staggered, should be ok.

the yam manual states which goes where for ring installation.

 

[Greasey Fingers]

Phew! Bloody haynes manual, maybe they just thought as long as they staggered who cares

 

[Greasey Fingers]

Hey just quickly, im anticipating first attempt to start her up for the first time since rebuild next session. What is the correct procedure to ensure its adequatly lubed before start up? Do i kick it over heaps without ignition on or battery connected to get the oil circulating then try fire it up? Will that send oil up to the top end? Whish me luck guys this is gonna be the moment of truth!!

 

[drewpy]

sparkies out, kick for 10 - 15 times, sparkies on, then she fires.....

 

[Greasey Fingers]

cool ill make sure i do that, hopefully you will here back from me tomorow telling you how it ran/runs

 

[Greasey Fingers]

Ok got another good session in!

STAGE 5

Valve clearances done, motor back in frame. Most of the fiddly electrics etc reconnected. Carbs/mufflers/air filters on. Blah blah blah. Ran out of time so didnt quite get to starting her up! All this refitting the motor takes longer than you think, all the little fiddly things are time consuming, lol. Next session will definatly be trying to start her up

 

[226dark]

Looking cleeeeeaaan, Greasey (no paradox intended).
Gotta love the fiddly things, ha.
Are you going to paint the black around the 'Yamaha" case cover? Looks good the way it is too The vapor blasting even blasted the yellow off the valve springs. When kickstarting you will see the oil pressure light go off immediately then back on but would agree that spark plug wires off and kick a dozen times. So I was wondering after a fresh rebuild, with you adjusting the valve clearance, valvetrain already worn in and that, do you still follow the periodic maintenance chart in owners manual? - for example: 1600km (1000mi), 3200km (2000mi), then every 6400km (4000mi) - or not necessary?

 

[Greasey Fingers]

Thanks mate Hmmm thats a good question, your asking me like i know though Yeah im not sure about that one maybe some else can hop in and clarify. I know that we will have to recheck them after the motor has settled in a bit.

 

[Greasey Fingers]

Very happy to report the REBUILD WAS A SUCESS! Wheeled her out today and she cranked over no worries and started right up. Let it warm up and took it for a spin and all the gears now work perfectly and motor is very nice and NO OIL LEAKS! Got a few electrical issues to sort but thats cool, im pretty damn happy all this hard work paid off

Also glad to wind up this thread cause even i was getting sick of it dragging on, cant imagine how much you lot were sick of it by now

Just want to say thanks for all the help guys, couldnt have done it without you or this forum Im really stoked, the sense of satisfaction is just great.

cheers guys!