Here’s my notes from the first phone call with the seller:
- Prior to rebuild: any evidence of crash damage? no - Straight frame? Yes and painted not powder coated (powder coat loses numbers) - German engine restrictions? No - Exhaust/head modifications to prevent cracking? yes. Tie rods fitted to underside and updated exhaust headers (factory spec upgrade) - New crank or reconditioned? Lying around or recent seals? Reconditioned crank -Cables condition? ok - Oil pump? reconditioned - Water pump: checked and fine - Suspension? fine. No pitting on forks. Front and rear damping good - Wheel bearings? new - Swing arm bearings? bushes good no play - Brake lines? new genuine; callipers: rebuilt - Clutch? new - Mirrors come with bike? Yes - Tank inside? Untouched. Fitted with new Yamaha fuel tap with internal filter - engine rebuilt. Cases vapour blasted. Recon exchange crank. New piston and rings gaskets + seals. Carbs refurbed and checked for correct jets. - Oil pump refurbished - exhaust ceramic coated - wheels powder coated and polished to original finish. New Avon tyres. - Fork legs brushed to original finish - wiring loom checked over and all functional - gearbox? standard and untouched - starts first kick - Oils used: Putoline 2 stroke: MX5 JASO FD fully synthetic. Putoline gearbox oil Light Gear 75w
This seemed interesting so I arranged a visit to the sellers workshop to see the bike in the flesh ....
So original tank was okay , just Norbo's was better? This thread is really intriguing because that bike looks gorgeous. I know pics only tell half a story but never would have guessed anything needs doing to it.
Next up, one of the fuel pipes came off the carb. Seems like the clear plastic pipes had hardened and both fuel pipes were only cable tied at the fuel tap end. Fixed with genuine black pipe and 4 clamps thanks to Norbo.
I checked the carb sync and they were out so I adjusted that correctly with the cables. The oil pump adjustment was spot on.
While I had the tank off to do this I checked all the wiring loom connections. Several were corroded and a couple were broken so fixed these and added anti corrosion spray.
There’s tape covering some holes in the airbox too:
I checked the clutch cable stiffness and the cable was routed incorrectly and felt notchy, making a right angle immediately after the adjuster at the bar. So I got a new Yamaha cable from Fowler’s and fitted it.
While I had the engine side cover off, I noticed that the front sprocket was quite worn although the bike had a new rear sprocket and chain. Also the safety tabs on the front sprocket were not bent over in their correct position (like some on the front discs) so fixed that.
Tackling the gear change problem revealed the lower gear change mechanism was rotating quite a bit around the gear change shaft. The splines were fine and a new part from Fowler’s cured the issue.
While there I noticed that the oil seal for the gear change shaft was not fitted correctly so sorted that.
The seat had been fitted incorrectly with the front plastic spigots bent out of shape but easily sorted.
Changing the gearbox oil after 250 miles revealed that the drain plug was over tightened and was very hard to remove. It was also fitted with a thin plastic or rubber washer. A new drain plug from Fowler’s luckily went in easily by hand with a new washer so I suspect it was the threads on the original (?) drain plug.
Next up the tank developed a leak from a seam and an inspection of the tank inside revealed a lot of corrosion so thanks to Norbo, I got a new tank beautifully painted. Here’s the original after winter in a dry storage bag:
350 fun miles on it and I’ve traced an annoying noise (which is speed dependent) to a faulty speedometer. I fitted a new Yamaha cable and replicated the problem in the shed with a drill. Still trying to work out what to do with this.
The seller insists ‘no warranty given or implied’ but hey, the fun I get out of riding the bike has outweighed the hassle.