PROJECT 900

man, I have to go clean my pants

 

The "donuts" should fix it. Glue the gasket to the valve cover with gasket sealer and then lube the other side with silicone grease or even a smear of motor oil. With new donuts it should seal up tight.

I fitted a new gasket and donuts to my '81 when I got it and I've had the valve cover off and back on at least three times since, no leaky.

 

I smear the Gasket Tongue Locating Channel with a tiny bit of Elmers Glue.
You have 15 Minutes to work with it before it stiffens.
Holds the Gasket in place and does not add an imbalance of sealant.
But, most of all. If the Gasket needs to be repositioned it gives.
And, ... Cleans-off with hot water.

Mount the Gasket on the Cover.
Position as accurately as possible.
Using tiny Paint Brush ... Coat Gasket Mating Surface.
Using tiny Paint Brush ... Coat Engine Mating Surface.
Mount Cover
Bolts Finger Tight.
Move Cover to insure Gasket Surface is Flat to Engine Surface.
(All the way around ... make corrections as needed)

Torque Fasteners
Gasket will PRESS Flat and SEAL.

 

Nice looking Wiz !! Don't ever sell it !

 

Thanks for the help, guys, I also have the leaky petcock syndrome & I thought it was good :?

 

It has taken you 148 days, so far, from June 10th to this far. I'd say "The End" date, but there's no such thing as The End date, but the statistics look like this including today as the "End Date"

4 months, 26 days excluding the end date. Magnificent!

Alternative time units:

148 days can be converted to one of these units:

12,787,200 Seconds
213,120 Minutes
3552 Hours
21 Weeks (Rounded down)
148 Days X 8 Hr Std Wk Day X $65.00 Hourly wage = $76,960.00

 

Rick that's some cruel mathematics there particularly making wizard work 7 days a week.

Great picture of the bike wizard looks fantastic.

 

I recon I need a raise. 8O

 

If there was any doubt, I was trying to turn my bike into one of these.

 

The leaky petchook, chuck the dang fool thing in the bin and get one of those old ones with cork seals or modify to remove vac', it can be done. The bike looks like it needs a bit of mother earth on it somewhere

 

He's puttin' an Aussie Dirtbag on it s soon as he gets it runnin'!

 

I think your 900 looks better than the XJR, they always looked a little plump to me.
The Wizard makes magic yet again.
Nice.
Glenn

 

Dammit, Wiz, that's MY XJR1300 you know...

Take the silly petcock apart and examine it with optical precision, you'll find the issue. If you rebuilt it with an aftermarket kit, the plunger probably isn't seating right; if it's the original the hollow o-ring might be holed.

Let me know what you find, I have some "raw material" that might help.

 

'Hollow O ring'.....where can I get a coupla them?? Reckon I'd pay a $1 each,including postage.

 

Petcock undergoing extensive testing, after re-seating using a 10mm dia disk of 1200 paper with a slot cut from the outside to the centre & using a new 9mm drill bit to turn the disc.

 

You do still have the in tank filter?

 

i more request wiz, a before and after pic, chop chop!

 

Yeh, sure do.

 

All previous pictures are HERE
as you requested, Schoot'.

 

Just took off the 'new' valve cover rubber gasket & it's in 6 bits, anyone seen the like?

 

My first reaction.

NOT the right part.
You know
I know
They obviously do not know.
Send it back.

 

31A-11193-00-00 GASKET, HD.COVER 1pc.

Incorrect Part Shipped.
Send it back.

 

And I thought it was a pulled thread. :cry:

 

Is that a cam bearing half?? NOOOO !!

Because they need to be align honed to match, if you get another.
Say it isn't so Wiz !!

 

No, it's one of the dummy ones that support the valve cover, thank goodness, still a PITA though, Time.

 

Got dem low-down PO blues again, eh Wiz? It seemingly never ends, at least at first. I'm still discovering little "traps" left by one of my POs.

That right there is why you CANNOT "tighten up" the valve cover bolts.

Check with chacal, they might be the same as the ones on the 750s, if so it's an easy scrapyard item.

 

A member is sending one to me.
This problem started by me getting an aftermarket gasket set, the valve cover gasket never fitted right, I know that now 'cos I bought a propper one from Yamaha, for lots of $$$$$ & it just dropped into the groove in the cover.
The a-market gasket leaked like a sieve & idiot, here, tried to tighten the cover down, I didn't know it at the time, but the bolt bottomed on the shoulder & started the crack.
So what have I learned? You might get away with a lot of a-m gaskets, but not the rubber vavle cover job, also, always change the rubber grommetts & never try to solve a leak by exceeding the specified torque settings. :cry:

 

post deleted

 

No, it wasn't from Chacal & don't worry he won't sell you something that's not fit for purpose.

 

post deleted

 

I know how you feel wizard. One of those valve cover brackets broke on my 900 too, when I was doing the valve shims. Chacal sent me another one, from a 650 or 750 motor and it fitted perfectly. I ran a thread tap and die over all the valve cover bolt threads, just to be sure it wasn't a bad thread that broke the old one.

 

Finally finished, I will post some better pictures when it stops raining.

 

Re: PROJECT 900 re Valve Cover Carrier Bracket

Hi Wiz,

Re the valve cover carrier bracket - I see you had the same problem as me. I was able to get one locally from a dismantled engine but I need another. Any chance where you got yours that they may have another?

I haven't tried chacal but next time I'm doing a service on the top end of the motor I'd like to replace one which has a stripped thread and another I'm becoming extremely suspicious about.

I believe that the threads can be replaced in them but seems easier to find a spare. I tried Yamaha and they said I could have one so long as I bought the head that went with it...!!!??? It individually is NOT a spare part.

Let me know if you can PM me or I might try chacal.

Good job on the bike - will have to try to get out your way soon when it stops raining.

Cheers,

Red

 

Nice looking bike man. Great job! I can't wait to see more pics of it.

 

Damn that looks good... Great work Wiz

 

Sunny pictures..........

 

ack wiz! second pair of pants ive had to clean from looking at this thread, nice work!

 

I wish my bike looked that tidy now...

 

GREAT JOB WIZ!!!!!!
Question thou,when you did your front brakes,did u replace your brake lines,did u get a quote for braided lines,do your front brakes work well??
reason i ask is i have the same bike without a resto job,just trying to get to understand the life of brake lines b4 some serious work is done on them.
sorry to bump this beatiful resto job on a classic bike!!!!!!!!!!!!!!!!!!!!!!!!

glad that i could help u on this project!!!!!!111

cheers albear

 

Hey wiz, love the angle of the can,what kind of can is it,sound is?i gather it is a 4 in to1, where u connect from 4 into 1is there a gasket there? & where u join onto ur can onto the collector box is there a gasket there.
gheers albear

 

Been on it yet...gloves on y hands, jacket and...sensible shoes, had the wind thru y helmet, speck of dust in the eye, cheshire grin on y face,
pulled in th drive n still can't stop stop grinnin?....wanna do it again...such
was the weather today. Bloody hope so!

 

Albear, the 4 into 1 is all one piece, I use clear silicone to make the joint between the muffler & the headers, I rebuilt the muffler, cut off the tail piece to have re-chromed & used 5 S/S pot scourers for baffles, sounds awsome. The brake lines were good, not soft or perrished & the brake works well.
Bushy, I will give her a run today & hope I don't get anything in my eye. lol.
You can take her for a spin, next time you come around. Wiz.

 

Dammit... you guys really need to stop making them look so nice, there's one not far away for sale for $1200.......

 

I can report that this is one very fast bike, in the mid rev band, awesome.
Woo Hoo. 8O

 

Wowza. Now that's a proper motorcycle. 8" headlight? Or even bigger?

Looks like your seat guy did a very nice bit of work.

 

Glad you like the finished product, Fitz, I think it looks better in the flesh than the pics'.

 

1st plug chop, I didn't go far, but I went quick & hit the kill switch @ 5K,
opinions please, Wiz.

 

It's a bit hard to tell, think you need close up with better light Maybe they got too much petrol down the line.

 

Would you mind doing a write up on the exhaust?
Or is it hidding somewhere in these 30 pages?

Thanks
ab

 

What did you want to know, Albran?
I had the headers ceramic coated (stirling silver) I took the muffler apart, replaced the fibre baffles wit S/S pot scourers & chromed the tail piece & pollished the ally can.