What did you do to your Yamaha today?

Hey rhys, I removed the fork from the bike and put it in a soft jawed vice such that the bottom of the fork was pressed against the floor. Basically the vice just steadies the fork. Then I was able to push down on the retainer using one hand and work the clip out with the other (and a screw driver).

Today I got my new carb intake boots installed. I had broken a couple of old the bolts off in the head. So I had previously drilled those out. But the threads were damaged. So today I used Heli-coil to repair the threads. That stuff is pretty slick. Now the boots are installed and torqued. Next task is sync and colortune.

 

rhys, I used a bar clamp while the forks were still assembled. I hooked one end under the turn signal stantion and pushed the spring retainer bolt down using a socket with the other end. Worked a treat because it let me use both hands to fish out that infernal clip. I actually had to make a special tool to get that out. I could shove the clip down but couldn't get it to come up. I finally took a piece of spring steel from a brake anti-rattle clip and bent a small hook into it to pull the clip past the groove. I think it took longer to get the first clip out than it did to do the rest of the job.

 

Rode the "old girl" to work all week after 14 years in storage!
(43 mpg)
The windscreen plastic mounts died on day two at 65 mph.

So now she has a new NC Plexistar 2 Windscreen.

Added hwy pegs, headlight visor and new tank molding.

Also, installed Russell braided SS front brake lines and banjo clamps!

What a difference, the Yamaha manual says to replace the rubber lines every four (4) years, well I was only late on that by 22 years!

 

14-Years ....

OMG ... You gotta be a candidate for Alumi-oxidation and a Fuse Panel.

Glad to hear it running good.
Congratulations!

 

Got to broken bolt on clutch lever mount fixed....
Next in line new brake lines and flush/clean etc.....

Also, still not happy with my improved signal mounts on the front.
Will be working up new ones this week.
Otherwise all seems well.

 

pulled carbs, cleaned and synched, didn't bench synch first time , ran good but not good enough. she runs out good now!!!

 

I re-covered my nasty looking seat with marine grade vinyl. It's not fancy, but I like it.

 

Hey wfuglaar, not bad!!

I was gonna ask "where" but I assume marine grade vinyl is bought at a boat dealer? Is that stuff slippery or OK for grip? My old seat needs a re-do and that looks like a great solution to sun and rain. What kind of staple and gun did you use? And how much material?

 

You can buy marine grade vinyl at Jo-Ann fabric. I believe it's 54 inches wide. Not sure they sell less than a yard, which would be more than enough for a seat.

 

A yard is just about right... the first half for the first attempt that got totally screwed up and the second half for the final cover.

 

Colortuned the Maxim and then synced the carbs. Took it for a 20 mile run and it ran great .

Now to rebuild the Petcock!

 

Cleaned up the new ride a little bit, and started it just for kicks. That didn't last too long!

 

I rushed out after tuning the 900 and went for a ride.
Hit the street running pretty damn good.
Moved through town heading for the highway while resetting the digital clock.
Got pizzed-off at myself for not remembering to reconnect the fuel sender plug-in.
Hit the highway warmed-up and opened her up 'til she hit the limiter ... saw 90 happen in third.
Started for home.
Started running bad but I had just installed a new, clean inline fuel filter.
Started running real bad getting-off the higway heading for home.
Rolled to a stop less than a hundred yards from the Harley Dealership.
Dead bike.
Switched to reserve but found the lever already in Prime.
Looked in tank.
Nothing.

Here's the good part.
A guy from Harley stops and gives me gas.
Still won't start.
Dead Bike. Long way from home.

Harley Guy drops the tailgate and lays-up the ramp.
Bike now in the back of the pick-up.
Tied-down good.

Free ride home courtesy of a Great Samaritan!
Unload bike at home.
Fresh set of sparklers get thrown-in.
Zoom, zoom, zoom!

But, I'm reworking the Tuning.
It had to be running Rich to foul those plugs after doing 90.

 

Swapped the rear wheel for a 5-spoker off an air-cooled 700/750. I like the look a lot better than the original "semi-disc" wheel.

Also put up a big shelf across the back of the garage for holding various bike parts. And rescued a throw-away bbq so I can modify the frame into a little rolling engine dolly, since I have a motor that's going to get worked on and painted.

Any recommendations for engine paint? I saw some Dupli-Color ones. I'm assuming the 1200* paint would be better for an air-cooled motor than the 500*. I guess I can use the 500* on X though... There was also something called Flame Paint, or something like that. Would that still be useful if I don't set the bike on fire?

Oh yeah... And when I was attending a charity event on Sat night, I ran into a guy who I hadn't seen for a few years but who used to ride a Max 650. Turns out he bought a Vulcan last summer and the Max has been sitting in his garage since. Says he sold it to some guy for $200 but he never picked up. Now he wants it out of the garage... He said if he doesn't hear from the guy that I can have it. Don't know if he meant that I can HAVE it, since it's already paid for, or if I can have it for $200. Either way, I'm gonna be in trouble with the GF when another bike shows up in the garage.... :wink:

 

PSteele

Thanks! It wasn't that tough to do.

I got my fabric at Hancok's. They were very helpful, and showed me to check the back of the fabric to make sure it was labled 'marine'. It was only $10 a yard, and was on sale for 40% off. My consultant/wife checked my measurements, so I only had to buy 2/3 of a yard. And yes, it was 54' wide. So I only spent $4.00 for the material! I also bought a small piece of 'NuFoam' and cut it to the shape of the top of the seat. This was not for extra padding, but to add a little more definition. (My consultant's advice.)

I took the old seat cover off, laid it flat on the new fabric and used it to cut the fabric to size and shape. I left enough extra on the cut to allow the fabric to be folded over for stapling purposes.

I used a regular utility stapler with 1/4' staples. It didn't do a great job., but I used a tack hammer on the staples that didn't go all the way down.

The biggest challenge was getting the 'puckers' out. I just went slow and pulled tight as I went. I had to pull out staples and restaple, but it turned out OK.

I also saved the old cover so I will have it as a pattern if I decide to try again and use two or three pieces of fabric instead of one, both for fit and style. Something like contrasting colors or some kind of center inset.

The seat is not slippery at all, but it is not a sticky as the goo left by the duct tape.

Bill

 

i put her together for the maiden voyage

 

Tested the spare CDI. Ran fine. Tested the CDI from the 750. Ran fine as well (sort of).

Found a way to get a big bar clamp on the spare set of 650 forks so I can get at the spring stop retaining circlip. Got the stop down to where I could see the clip - MUCH RUST! - and then realized that when I remove the circlip and then release the tension in the bar clamp, I don't know where that spring is going to go.

Rather than fire fork parts all over the garage, I left the circlip where it is and just removed the bar. Will think about that some more tomorrow. Too tired to play with it any more.

Oh, the test rides on the 650 to prove the CDIs good was rather enjoyable, even if it's about 50 degrees out with a chill wind. Buttoned up that jacket and it was pleasant! Haven't spent NEARLY enough time on two wheels this past year.

 

Yesterday...

1) Replaced original fuse panel with inline ATO weatherproof holders using solder and heat-shrink tubing.

2) Applied snap-on wire protectors to wire bundles under the seat.

3) Cleaned battery terminals and applied silicone grease.

4) Checked torque on all fasteners 10mm and above.

It seemed to start more readily after the electrical upgrade. Bonus.

 

Did a plug chop. Cylinders 1 and 3 and lean. 2 and 4 are marginal. Tweaked the mixture screws, but will be buying two sets of main jets (next two sizes up) and getting the lean condition corrected before I ride much more.

 

Sunday went for ride, noticed the slight rattle at idle and slow riding has turned into a steady knock that rises with rpm's. Monday i pulled a few covers and the bottom pan and found the telltale metal shavings and notice wear on the main bearings so....tuesday go to the local parts guy and buy a 20k mile XJ750 motor for $150. Hopefully saturday we will pull the old motor and install the new motor. I realize i will have to get an aftermarket tach and will have to replace the ignition pickups and such, but this motor needs the pickups, alternator and starter anyway so no big. Looking forward to a bit morer pep and riding again ( I know its only been a week but I am jonesing already). cruzerjd