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Post by yamark on May 15, 2022 19:57:23 GMT 1
I managed to find time to make crankshaft and gearbox dummy shafts for welding future engine cases. I used thickwall steel tube, welded extra sections on and reduced to size on the lathe. I could have used solid bars, but they weigh a tonne! The bars allow for 3 or 4 cylinder engines, rd250/350/400, 250/350lc and YPVS, so I can build whatever engines that spare parts allow. SDC12183I built up the crankshaft, and trued it to under half of Yamaha's run out specs SDC12171 I then bolted the cases together to check for any binding SDC12172 I feel like I'm over the hurdles and racing toward the finish line, but can't help but feel there's a sting in the tail somewhere. Cheers, Mark
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Post by dusty350 on May 15, 2022 20:33:37 GMT 1
Looking awesome mate I know how much planning you've put into this. I fully expect you to cruise to the finish line, all hurdles overcome Gonna be a stunner !!
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Post by donkeychomp on May 15, 2022 21:15:26 GMT 1
That crank! Hopefully no stings in anyone's tail Mark.
Alex
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Post by sidney81 on May 15, 2022 22:26:00 GMT 1
Fantastic 😎
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Post by Denzil on May 16, 2022 13:23:29 GMT 1
OMG Mark, that is a thing of beauty. Love the attention to detail that goes into your builds.
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Post by bezzer on May 16, 2022 22:14:04 GMT 1
Mark, Some fantastic engineering Q&A’s in your latest update. The penny has now dropped with me on the use of a YPVS clutch actuator, on reading your reasoning behind it. I hadn’t even considered cable routing, also exaggerated by the increased engine width etc. Hats off to your pre planning mate, you have really thought this out fantastically well. Like everyone following this build I can’t wait to see it completed, not long now buddy.
Bezzer
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Post by tacky1 on May 17, 2022 2:07:37 GMT 1
Looking the biz Mark,
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Post by mouse on May 17, 2022 6:43:40 GMT 1
That is quite some feat of engineering, amazing!
Mouse
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Post by arrdy350 on May 17, 2022 6:49:36 GMT 1
Excellent job. I can't wait to see finished 😃👍 It is a shame Practical sportsbikes don't do shead build of the year anymore.
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Post by steeley on May 17, 2022 8:19:53 GMT 1
Nice .
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Post by zig on May 17, 2022 10:34:09 GMT 1
great work
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Post by abar121 on May 17, 2022 13:07:22 GMT 1
Just wonderful. What a beautiful motor you are building. Love it.
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Post by yamark on May 23, 2022 18:31:30 GMT 1
Sorry it's a day late . Thanks chaps for your fantastic comments and enthusiasm, it really does spur me on. I managed (with help) to get the engine in the frame. It is heavy . I thought I'd fit everything else, clutch, generator, cylinders etc after fitting the bottom end. SDC12176 This next image, shows the new route for the neutral switch wire, with it's heatproof cover SDC12182 I also installed the engine breather at an angle so the pipe could be hidden behind the frame tube. SDC12187 Lastly, the clutch arm and brackets SDC12185Cheers, Mark
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Post by donkeychomp on May 23, 2022 22:15:48 GMT 1
It's looking more like a bike each week! I'm still stunned by this. The sheer amount of thought and work that has gone into it. Fantastic stuff Mark.
Alex
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Post by mouse on May 23, 2022 22:26:47 GMT 1
Now this is starting to look like something i recognise, looking great!
Mouse
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Post by charles13 on May 24, 2022 0:33:12 GMT 1
Sorry it's a day late . Thanks chaps for your fantastic comments and enthusiasm, it really does spur me on. I managed (with help) to get the engine in the frame. It is heavy . I thought I'd fit everything else, clutch, generator, cylinders etc after fitting the bottom end. SDC12176 This next image, shows the new route for the neutral switch wire, with it's heatproof cover SDC12182 I also installed the engine breather at an angle so the pipe could be hidden behind the frame tube. SDC12187 Lastly, the clutch arm and brackets SDC12185Cheers, Mark After every post you make on this project I’m just gobsmacked, wow amazing
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Post by yamark on May 29, 2022 20:51:32 GMT 1
Thanks, Alex, Mouse and Charles13 . I forgot to post last week, the parts for the clutch arm, tacho drive and idler SDC12184And fitted SDC12186Now, here's a weird bit. I thought I'd check the neutral light was working(nearly all the electrics are finished). Remember the neutral switch is buried inside the outrigger section. No neutral light! I earth the light blue wire(at the generator plug) and the light works on the clocks. I've run a separate engine earth and my neutral wire to the switch is new. So I check continuity of the new neutral wire, and also check continuity for the engine earth, both show no resistance, so all good. That leaves a switch fault, selector drum neutral post fault or the drum not aligned The switch is Gen Yam and new, this is weird. The joys of special builds
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Post by donkeychomp on May 29, 2022 21:30:14 GMT 1
Shazbot! Hope it's an easy fix Mark.
Alex
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Post by yamark on Jun 5, 2022 19:01:35 GMT 1
Neutral switch . I had to take the engine out and split the cases to see why the neutral switch didn't earth. I took no chances, changed the selector drum, measured the switch contact was touching the post on the drum. It all checked out, I did a continuity check to double check. Then I resembled the cases, so nearly back to where I was. The next day, I did another continuity check, and the check failed! When I looked at the neutral switch, the brass contact (which is smaller on the new switches than the originals), was a fraction below the surface. I replaced it with the best used one I had and it worked. I then checked it a few more times before re-installing the engine. It now works as it should, so it has to be a faulty new Gen Yam switch. With the bottom end back in, I assemble the clutch I use a 1"1/8 socket as it fits the clutch nut perfectly SDC12188 And primary drive nut, using a bit of copper tube to stop the gears from turning SDC12189 Cylinders have been painted and ready to be fitted so I can work out the squish SDC12191 SDC12192 And heads SDC12193 The neutral light is still working Cheers, Mark
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Post by donkeychomp on Jun 5, 2022 21:57:19 GMT 1
Fantastic! Paint looks very good Mark.
Alex
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Post by bezzer on Jun 7, 2022 23:19:39 GMT 1
Well done on finding the neutral light issue Mark, just goes to show, even with genuine Yam or NOS parts, we should never take for granted their suitability for purpose!. Cylinders and heads look great bud, as does the engine in the frame. Congratulations mate ~ finish line in sight! 👍🏻
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Post by mouse on Jun 8, 2022 5:55:30 GMT 1
Glad you got the neutral switch sorted, what a bl***y nightmare!
Mouse
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Post by abar121 on Jun 8, 2022 20:36:49 GMT 1
What a pain with the neutral switch! Glad it's sorted now.
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Post by yamark on Jun 12, 2022 15:47:46 GMT 1
Thanks lads, neutral light is still working . Going back to the crankshaft, I was on the Fowlers website, and thought I'd price the parts for the 4 cylinder crank, full Yamaha price. Remember I'm using 250E/F inner webs/main bearings and LC outer webs/main bearings/conrods LC RH bearing £57.47 LC thrust washers £5.50 X 8 £44.00 LC B/E bearing £46.55 X 4 £186.20 LC conrods £98.38 X 4 £393.52 LC LH bearing £64.30 E/F center bearing £69.43 X 6 £416.58 E/F crankpin £30.43 X 4 £121.72 LC small end ends £26.41 X 4 £105.64 Total £1389.43 - that's just the parts, re using lab seals Back to build, I assemble the top end to work out my base gasket thickness to determine the squish. SDC12194 I then contacted Rob (4L04ever) to make the base gaskets the thickness I need (and all remaining gaskets, except head gaskets) If you've never dealt with Rob, start now, he's fast, true to his word and very reasonably priced, brilliant to deal with - he also re bushed my idler gear. I also install my reed valves and new inlet rubbers SDC12195 I can now install the clutch url=https://flic.kr/p/2nrvp5b]SDC12196[/url] You have to fit these spacers for Muttsnuts lock up clutch SDC12197 Then the ball bearings are fitted and the pressure plate fitted SDC12198 And tightened, this all fits below my modified clutch cover SDC12199The generator/ ignition is next week Cheers chaps, Mark
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Post by yanksmoker on Jun 12, 2022 18:23:25 GMT 1
Damn, this is so AWESOME! Truly great work, I can't wait to hear it start up for the first time all the way in Oregon!
Yanksmoker
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Post by dusty350 on Jun 12, 2022 18:30:33 GMT 1
Looking fantastic Mark Truly awesome Dusty
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firebird67
L plate rider.
2 strokes forever 😍😍😍
Posts: 31
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Post by firebird67 on Jun 12, 2022 20:54:43 GMT 1
Looking amazing, glad you sorted the neutral light problem, Looking forward to seeing it finished 👍
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Post by steve63 on Jun 12, 2022 21:18:00 GMT 1
Ooh, getting exciting now 😀
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Post by donkeychomp on Jun 12, 2022 21:49:36 GMT 1
Looks fantastic Mark.
And +1 for Rob. Gaskets are just one of his talents...decals too!
Alex
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Post by sidney81 on Jun 12, 2022 22:20:33 GMT 1
Awesome 😎😎😎
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