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Post by dusty350 on May 23, 2020 19:40:25 GMT 1
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Post by dusty350 on May 24, 2020 21:16:16 GMT 1
Got the barrels on this morning, aided by my lad. He supports the barrel as I compress the rings.  20200524_103906 by dusty miller, on Flickr I used 4 Yamaha inlet gaskets;  20200524_112835 by dusty miller, on Flickr I used 4 because I have fitted a billet intake I bought from Mutts. He drilled and fitted oil feed spigots for me too  ;  20200524_165644 by dusty miller, on Flickr  20200524_121253 by dusty miller, on Flickr The feeds were needed as I also bought a pair of new Pwk 28's which don't have an oil feed inlet as standard. I also needed to final fit the rotor, so first removed the generator to make fitting the woodruff key easier;  20200524_123839 by dusty miller, on Flickr I torqued the rotor nut up, using the locking tool to hold it safely;  20200524_131445 by dusty miller, on Flickr Just the heads to go on next and refit the barrel studs, and the top end is done. Dusty |
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Post by 1966baz on May 25, 2020 19:17:22 GMT 1
Great thread Dusty.I had an air cooled rd 400 DX 30 years ago.Restored it on a budget and sold it for £400.
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Post by dusty350 on May 25, 2020 20:07:54 GMT 1
Hi Baz Cheers. I think a few guys on here have own aircooleds in the past. They were the hooligan bike before the Lc's !! Nearly there now. Heads on today. I managed to source some genuine head gaskets from Germany;  20200525_141000 by dusty miller, on Flickr And the rubber cushions for the head fins came from Norbo;  20200525_141047 by dusty miller, on Flickr And trying to find some nice head bolts isn't easy - not like for the Lc and Pv's anyway. I did clean up the originals a bit but I knew they wouldn't be good enough, so I swapped them for the nice stainless ones on my 430 !!;  20200525_100628 by dusty miller, on Flickr  20200525_140908 by dusty miller, on Flickr I will find some others for the 430 ! So the heads went on, with new spark plugs too. Just need to order 2 more fin cushions as I've ended up using 8 per head instead of 7  ;  20200525_151438 by dusty miller, on Flickr  20200525_151447 by dusty miller, on Flickr Then I fitted the Pwk's, for good measure;  20200525_152752 by dusty miller, on Flickr  20200525_155015 by dusty miller, on Flickr Just need to check the timing and do a pressure test, and sort the side cases for paint. Oil pump to Arrow, and buy a pair of foam pods. Dusty |
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Post by donkeychomp on May 25, 2020 22:19:08 GMT 1
Looking great Dusty! Let me know what filters you opt for as I need a pair...
Alex
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Post by oldbritguy on May 25, 2020 23:57:47 GMT 1
What a job on that motor Dusty Absolutely stunning mate. Of course, we would have expected nothing less  Top draw. |
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Post by dusty350 on May 26, 2020 7:41:08 GMT 1
Cheers fellas Alex, I will probably get some standard Ramair foam pods for it. I don't think I will need the angled filters I bought for the Café bike on this build. I plan to weigh the engine once it's complete with side cases. It will be interesting to see how much heavier it is than an Lc engine. It does feel considerably heavier. You can see how Yamaha must have looked at this and designed the Lc to have less parts, and also save weight by using more plastic where possible. It's another easy engine to build though, and well within the capability of anyone with time, patience and some tools. Not cheap though - it certainly cost more than an Lc, like for like. Some things seem better - the splined crank is strong, but heavy, so you wont want to over rev it, it' nice the head gaskets are reusable, and Yamaha base gaskets for the 400 cost £7.69 each as opposed to an F2 costing £23.74 ! There are far more trick parts available for the Lc/Pv if that's your thing, but you can get some bits for these. Parts like a gear change shaft are nla, and the Shambits one they sell doesn't fit properly apparently ! Oil pump could be a headache. I've sent pics to Arrow, and what I have is a real mismatch, with some parts nla for the pump and drive, so it will only get built if Gary can sort parts. After doing a few Lc and Pv engines in a row, it's come as quite a challenge to get this built to the standard I want. Paul at PJME did a brilliant job of the crank and rebore, and uses only top quality parts, so that's reassuring. Fowlers had most parts in stock for next day delivery, so that's good too, and certain parts are shared across to the Lc engine, so some used parts are easily found too. Hope it helps anyone choosing to build one in the future Dusty |
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Post by steeley on May 26, 2020 8:54:10 GMT 1
Nice job there dusty . Years ago i had a 400c i loved it and had it for some years . Had the motor stripped down once i think it was a crankshaft job . Had a re bore done on it and the firm bored it out to ypvs clearance . I ended up with 1.25 o/s pistons in it .Ran it for about a year then sold it on ,wish i still had it . Yes the lumps are much heavier than the lc .
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Post by arrow on May 26, 2020 9:13:34 GMT 1
Its a great build Dusty, as always.
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Post by ridgmeister on May 26, 2020 9:13:43 GMT 1
That's a really nice build - I never had a 400 but a couple of my mates had late model 400s in white/red but that was beyond the wages of an apprentice, at the time.
Paul
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Post by sidney81 on May 27, 2020 10:31:18 GMT 1
That's lovely dusty what a great job , I was also surprised how heavy my 250 air cooled engine was compared to my Tzr engine ..
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Post by midlifecrisisrd on May 28, 2020 21:40:27 GMT 1
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Post by arrow on May 28, 2020 21:53:58 GMT 1
Wow! Thats a lot of money for two bits of aluminium! |
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Post by dusty350 on May 29, 2020 7:33:30 GMT 1
The radial heads are being remade in the US, so you can buy them new as well, around £500 posted I think  I did seriously consider them at the start of the build, but couldn't justify the expense, especially when my standard heads were detonation free and in really good nic. Plus, after research, they are reported to be noisier than standard - resonating fins I guess, and don't offer much, if any, performance gains, so it would have been purely an aesthetic upgrade. They do look cool though, and the newer design has the longer bottom fin which looks much better where it meets the barrel fin; www.google.co.uk/imgres?imgurl=https%3A%2F%2Fcdn11.bigcommerce.com%2Fs-2dn0q4%2Fimages%2Fstencil%2F1280x1280%2Fproducts%2F1780%2F3165%2FRHSC350SF6__49886.1433361569.JPG%3Fc%3D2&imgrefurl=https%3A%2F%2Fhvccycle.net%2Fyamaha-rd350-r5-performance-heads-rhsc350%2F&tbnid=1Kzv-7sbC8yKgM&vet=12ahUKEwjB9byfuNjpAhUW_4UKHTmrCC8QMygUegQIARAo..i&docid=2RI2QZBWIKperM&w=1280&h=854&q=rd400%20sunburst%20radial%20heads&safe=strict&ved=2ahUKEwjB9byfuNjpAhUW_4UKHTmrCC8QMygUegQIARAoRevco heads are even more whacky, and pretty rare. They are watercooled heads that bolt onto the aircooled barrels; www.google.co.uk/imgres?imgurl=x-raw-image%3A%2F%2F%2Fc3b1e483abcb0e201072d95c7657847fc8ff06c858b877157382f207d66fd8d8&imgrefurl=http%3A%2F%2Fwww.eurospares.com%2Fgraphics%2FYamaha%2FMX175B%2FYamaha%2520RD350_400%2520aftermarket%2520cylinder%2520head%2520info..pdf&tbnid=IA7Lq4PkscPYgM&vet=12ahUKEwjd8JaAudjpAhURVhoKHZA9CTUQMygBegUIARDQAQ..i&docid=z-IJc3fhYOzQnM&w=639&h=480&q=rd400%20revco%20heads&safe=strict&ved=2ahUKEwjd8JaAudjpAhURVhoKHZA9CTUQMygBegUIARDQAQYou can also get Toroidal heads; www.google.co.uk/imgres?imgurl=https%3A%2F%2Fwww.economycycle.com%2Fwp-content%2Fuploads%2F2015%2F10%2Fsuperiorwebcoheads1.jpg&imgrefurl=https%3A%2F%2Fwww.economycycle.com%2Fshop%2Fyamaha-rd250350400r5ds6ds7-parts%2Fengine-related%2Fheads%2Fsuperior-heads-sp1-toroidal-chamber-design-o-ring-gaskets-sandcast-the-best-heads-you-can-put-on-your-rd%2F&tbnid=QlJnWFJo03ulGM&vet=12ahUKEwjd8JaAudjpAhURVhoKHZA9CTUQMygSegUIARD1AQ..i&docid=Xz4TpPooQ0_0_M&w=800&h=533&q=rd400%20revco%20heads&safe=strict&ved=2ahUKEwjd8JaAudjpAhURVhoKHZA9CTUQMygSegUIARD1AQI can buy a new pair of Allspeeds for the cost of any of these heads, so they will have to wait for a future build !! Dusty |
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Post by dusty350 on Jun 3, 2020 19:52:17 GMT 1
Got one of Simon's (siberdyne) clutch covers this week;  20200602_133946 by dusty miller, on Flickr  20200602_133951 by dusty miller, on Flickr I think I'm going for Cerakote on this and the left side casing so it matches the barrels and heads, so Simon supplied it in a blasted only finish. Hopefully drop it all off to Jamie tomorrow. Gary has the oil pump so that's in hand too. I lightly polished the clutch pressure plate this afternoon and have some Ti bolts on there way from Martin at Mbd. Just felt the engine needed a little "something" to finish it off Dusty |
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Post by donkeychomp on Jun 3, 2020 22:07:09 GMT 1
Really neat Dusty!
Alex
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Post by oldbritguy on Jun 4, 2020 7:50:42 GMT 1
That is looking fantastic Dusty. I had never heard of that particular type of coating until your builds and I like it very much.
This engine is a work of art and will no doubt end up in a bike of equally high standard 😉
Looking forward now to the next steps
John
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Post by dusty350 on Jun 5, 2020 19:30:22 GMT 1
Thanks fellas The side casings were dropped off to Jamie yesterday - will be a couple of weeks due to his workload. If the satin powdercoat is a good match for the Cerakote, then he will go with the powder, or if not the cases will get Cerakoted. It's quite a thin finish so may show up a few marks in the cases. Chatting to Jamie, it turns out he had "some bloke called Hag Hughes" in the other week, getting his Lc frame and wheels blasted by Jamie, so Hag might be building another Lc !! Cant do too much now until the cases come back, but I did treat the pressure plate to some bling in the form of gold anodised Ti bolts from Martin at MBD;  20200605_151934 by dusty miller, on Flickr I gave the pressure plate a light polish first - you only see the centre part with the bolts so no point going too mad. Also found two odd Ramair filters that I fitted - I will get new ones eventually;  20200605_151943 by dusty miller, on Flickr Also set the timing yesterday. Yamark popped over, and I used the dial gauge adapter he kindly made for me on his lathe;  20200604_081148 by dusty miller, on Flickr  20200604_081233 by dusty miller, on Flickr Fits perfectly He's a clever boy - you'd think he been using lathes all his life !! Dusty |
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Post by dusty350 on Jun 11, 2020 20:32:20 GMT 1
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Post by donkeychomp on Jun 11, 2020 21:49:57 GMT 1
That clutch is very snazzy Dusty. If you don't mind me asking how much was it?
Alex
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Post by dusty350 on Jun 11, 2020 22:04:54 GMT 1
£109.00 on an exchange basis. Simon can supply just the bezel, glass and fitting kit though if you get the hole cut yourself. He is on the forum -siberdynemotorcycleparts. Nice guy. Dusty |
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Post by donkeychomp on Jun 11, 2020 23:14:33 GMT 1
Thanks for the info. I'm tempted lol.
Alex
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Post by dusty350 on Jun 13, 2020 20:18:06 GMT 1
Little job done but important none the less. One of the last freezer bags of parts was opened today - the clutch actuator worm drive;  20200613_101427 by dusty miller, on Flickr Pretty grotty as you can see. Covered in chain grease and gritty deposits, it was well overdue a bath in some clean petrol;  20200613_111911 by dusty miller, on Flickr  20200613_111854 by dusty miller, on Flickr Repacked with fresh grease it now works as it should. There is a ball bearing inside the mechanism, and that was moving freely by the time I finished, so that was good. Another part nearer to a completed engine !! Dusty |
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Post by Tobyjugs on Jun 13, 2020 20:34:07 GMT 1
Those cases look great.
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Post by arrow on Jun 13, 2020 20:37:57 GMT 1
Cases look amazing. Pump should be with you this coming week.
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Post by dusty350 on Jun 14, 2020 9:52:58 GMT 1
Really pleased with the cases - Jamie does a great job Cheers Gary - look forward to bolting that on Dusty |
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Post by yamark on Jun 14, 2020 19:01:51 GMT 1
I popped over to Dusty's about a week ago and this engine is simply perfection. I'm still not sure how his engines sparkle! Smoke and mirrors and a bit of Mr Sheen is my guess 
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Post by dusty350 on Jun 20, 2020 16:11:09 GMT 1
The oil pump that came with the engine looked rough;  20200525_204406 by dusty miller, on Flickr I was keen to keep the pump, so sent it off to Arrow to see what could be done. This one was a bit of a challenge for Gary I think, due to mismatched parts and availability issues with ac pumps. But, as always, Gary has done an amazing transformation;  20200620_133311 by dusty miller, on Flickr Better than new ! And he supplied the correct drive shaft for it too. It's about time Gary was recognised by the Queen for services to Rd owners !! Arise "Sir Gary", you have excelled once again Thanks again mate, it's great Dusty |
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Post by arrow on Jun 20, 2020 17:00:33 GMT 1
Happy to help mate, and that old C/D wormshaft in your photo is starting a new life too.
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Post by dusty350 on Jun 27, 2020 14:19:00 GMT 1
That's good news Gary, glad it helped someone out Finished the engine today (well virtually !!) Fitted the oil pump that Sir Gary rebuilt. New Yam seal;  20200627_095821 by dusty miller, on Flickr Some red rubber grease around its outer edge and then drawn into place with a bolt, washers and a nut;  20200627_100715 by dusty miller, on Flickr The new worm drive and spacer go in the other side, not forgetting the tiny shim on the end of the drive;  20200627_110439 by dusty miller, on Flickr New clutch gasket;  20200627_104131 by dusty miller, on Flickr Side case now bolted up finally. Oil pump fitted, and gearbox oil added to check for any leaks - thankfully none !  20200627_114025 by dusty miller, on Flickr Need to get another litre of gear oil as I only had 900ml, so that's been ordered. May spray the inside of the genny cover satin black as it's bare alloy where Jamie blasted it, plus I need to get new oil lines and the rubber flap on the inside of the genny case, but other than that, it's done ! Oh, I also blinged the genny cover with one of Simon's covers;  20200626_180025 by dusty miller, on Flickr I wasn't going to do it originally, but changed my mind ! He machined my newly powercoated cover with no problems. I think it looks great Dusty |
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