Restoration Project

 


1967 Yamaha YR1 350

Presented by cyclelist


Pictures


Right Side   2009-04-30 09:20:24 Left Side   2009-04-30 09:20:43 Front Wheel   2009-04-30 09:21:07 Guages   2009-04-30 09:21:48 Rear Fender   2009-04-30 09:23:26
Rear   2009-04-30 09:24:29 Left Muffler   2009-04-30 09:23:52 Muffler   2009-04-30 09:22:11 Engine Off. Everything was there, no mssing parts.    2009-05-03 07:52:15 On the bench, ready to take apart.   2009-05-03 07:52:47
Start with the right side. I did notice that the oil lines were loose on the cylinders, could have caused the problem with the bearings.    2009-05-03 07:53:52 Casing off, one clutch piece was broken off, someone had not had the propper tool last time clutch was taken off....   2009-05-03 07:56:45 Oh yeah, had to make a tool to hold the clutch while I loosened the shaft.    2009-05-03 08:29:19 Cylinders removed, pistons look good, wrist pin bearing is worn out.   2009-05-03 07:58:05 Connecting rods seem ok, will have to check the specifications.    2009-05-03 08:00:10
Flipped the engine and loosened all of the bolts, time to split the casings.    2009-05-03 08:00:53 Engine split easily, hellow, what is the spring at end of red arrow and where did it come from?    2009-05-03 08:05:29 Crankshaft bearings were toast, should probably replace connecting rod bearings while I All apart, I think everthing is shot, will need to spec it out. Did Yamaha make a rebuild kit?   2009-05-11 06:39:51 Initial press of other half, made plugs for rough alignment, the wrong way to do this...    2009-11-17 07:07:59
Pressing connecting rod lower pin in.    2009-11-17 07:06:45 Almost done the last press.    2009-05-11 06:38:47 Two sides together, now for the final alignment.    2009-11-17 07:10:05 Checking the alignment on the lathe of one half. Time for some v-blocks.    2009-11-17 07:10:47 Pressing the two pieces together   2009-11-24 11:18:52
Notice pieces of surface ground metal to stop cranks from squeezing together   2009-11-24 11:19:43 Together finally   2009-11-24 11:20:22 Crankshaft in homemade vblocks measured by dial indicators   2009-11-26 01:15:29 All the new parts ready to go back in.    2009-11-17 07:05:05 Before Bottom Casing   2009-11-30 10:32:15
Front of Top Casing with beginning polish started.    2009-11-30 10:33:42 Top casing with a lot of polishing already done.    2009-11-30 10:32:51 Checking that all bearings purchased actually fit.    2009-11-17 07:08:58 Putting on sealant   2009-12-29 01:11:47 Crankshaft, Transmission and Kickstart aligned properly after three attempts! Let the assemble continue!   2009-12-29 01:12:47
Clutch on, casing on.   2010-01-11 07:13:54 Putting the engine back on.    2010-04-06 12:00:29

Log Entries


Title: Picked up the Bike!Hours: 2 Cost: $650.00
Work Descrption: Had my brother-in-law pick up the bike today. Its in average shape. Numbers match between engine and frame.


Work Start Date: 2009-05-03  Work End Date 2009-05-03
Title: Split EngineHours: 2 Cost: $0.00
Work Descrption: Removed engine and split the casings. Now decisions need to be made about rebuilding the engine.


Work Start Date: 2009-05-10  Work End Date 2009-05-10
Title: Pressed Crankshaft apartHours: 1 Cost: $0.00
Work Descrption: Pressed the crankshaft apart. Took a lot of force but eventually popped apart. Will need all main bearings. Connecting rod journalls looked worn. Connecting rods may also be shot. Connecting rod bearings surely shot as are the wrist pin bearings.  All seals toast, may also need aluminum labrynth  seal in the middle.


Work Start Date: 2009-08-23  Work End Date 2009-08-23
Title: Tracked down and ordered parts.Hours: 2 Cost: $0.00
Work Descrption: Looked on several sites to find parts. Tracked down a lot of obsolete engine parts on boat sites. Some on ebay.


Work Start Date: 2009-11-14  Work End Date 2009-11-25
Title: Reassembled CrankshaftHours: 8 Cost: $0.00
Work Descrption:

Had to make a lot of tools to get the crank back together. Vblocks, spacers, pullers.. It's back together and on reading very little wobble (within 1/1000) so I believe its ready to assemble.  Spent a lot of time on this, but it was a good learning experience. Took time to make specialized tools.

 Will wait for second opinion before re-installing into engine block.



Work Start Date: 2009-11-29  Work End Date 2009-11-29
Title: Cleaned Engine CasesHours: 1 Cost: $0.00
Work Descrption: Started Cleaning Engine cases. Initialy Cleaned cases in parts cleaner, that got most of the grease off. Found that a dremel with a small wire brush will clean up everything the parts washer could not.


Work Start Date: 2009-12-28  Work End Date 2009-12-28
Title: Started AssemblyHours: 2 Cost: $0.00
Work Descrption:

Put in crank, transmission, and Kickstarter. Covered casing surfaces with silicone sealant. Assembled, checked kickstart, it was wrong... Took it apart again, then put it back together again... Seal in backwards, Apart again... Together again...

 Made new shift spring. Cleaned up casing bolts.



Work Start Date: 2010-01-10  Work End Date 2010-01-10
Title: Right Case and Clutch on.Hours: 1 Cost: $0.00
Work Descrption: Buffed some more of right case, also assembled clutch and put cover on.

To Do Entries


Title: Put Engine Back TogetherHours: 0 Cost: $0.00
Work Descrption: Must put the engine back together.


Title: Find Brushes for GeneratorHours: 0 Cost: $0.00
Work Descrption: Need to get brushes for the generator

Total Cost: $650.00    Total Hours: 19


Parts Wanted




Name
Category
Desired Cost
Date Entered
Part Description
CylinderEngine$0.00 2009-05-04

Might want to replace the cylinder, one fin chipped. Or, may see if I can get the fin repaired.

Clutch Basket?Engine$0.00 2009-05-03Old one is busted, but will still work.
Generator BrushesElectrical$0.00 2009-05-05

Bike needs new brushes for the generator

Engine cover screwsEngine$0.00 2010-01-12Many engine screws are stripped, would be nice if new ones could be put on.

Parts Purchased







Name
Category
Cost
Date Entered
Part Description
Crankshaft BearingsEngine$129.94 2009-08-27

Found two so far.

GasketsEngine$25.00 2009-09-15Purchased all gaskets.
wrist pin bearingEngine$0.00 2009-09-15Purchased two bearings, waiting for parts.
ManualDocumentation$20.00 2009-08-27Will need a manual to check the specs and see where the spring flying around in the engine came from....
Point CoverEngine$44.99 2009-08-24NOS from thailand.
Connecting Rod Lower BearingsEngine$30.00 2009-08-27Purchased from ebay.
Connecting RodsEngine$122.84 2009-08-27Found on a boat site, purchased, hope their inventory is correct.

Total Cost: $372.77




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