Project 1976 Yamaha YZ400

Discussion in '2 smokers' started by craydds, Feb 22, 2013.

  1. craydds

    craydds Long timer

    Joined:
    Aug 3, 2010
    Oddometer:
    1,176
    Location:
    Las Cruces, NM
    JB Weld sanded smooth:
    [​IMG]

    Coat of paint:
    [​IMG]
    #41
  2. dtysdalx2

    dtysdalx2 PITA but useful

    Joined:
    Aug 1, 2004
    Oddometer:
    14,819
    Location:
    Moneyapolis, MN
    Looks like fun! Glad it's all there.

    Pics when done! :wink:
    #42
  3. Scootern29

    Scootern29 Been here awhile

    Joined:
    Sep 4, 2012
    Oddometer:
    795
    Location:
    In the hot, hot, dezert
    I just noticed something. The head on your bike is not stock. Is it a Webco or?
    #43
  4. craydds

    craydds Long timer

    Joined:
    Aug 3, 2010
    Oddometer:
    1,176
    Location:
    Las Cruces, NM
    You must know more about that than me, I did not even notice. Guess I'll have to do some research.
    #44
  5. craydds

    craydds Long timer

    Joined:
    Aug 3, 2010
    Oddometer:
    1,176
    Location:
    Las Cruces, NM
    Theses are AIR forks! Actually held air pressure:
    [​IMG]

    Time for fresh fork oil and seals, too:
    [​IMG]



    These are the upper, high pressure air chambers:
    [​IMG]
    #45
  6. craydds

    craydds Long timer

    Joined:
    Aug 3, 2010
    Oddometer:
    1,176
    Location:
    Las Cruces, NM
    Good time to clean and lube the steering head. There was dried up old grease and dirt in there. That upper race does not look very smooth, but I am going to grease it and give it a try. If it feels rough after assembly I will get all new bearings later:
    [​IMG]

    Paint on the triple clamps, and shining up all the parts:
    [​IMG]
    #46
  7. craydds

    craydds Long timer

    Joined:
    Aug 3, 2010
    Oddometer:
    1,176
    Location:
    Las Cruces, NM
    Totally disassembled and cleaned the brakes:
    [​IMG]

    Did I get those springs right? It looks like two different springs. Which one goes on the right and which on the left?
    [​IMG]

    A bit of paint and polish:
    [​IMG]
    #47
  8. Valleyrider

    Valleyrider I Survived The '60s

    Joined:
    Apr 12, 2007
    Oddometer:
    1,896
    Location:
    Idaho Panhandler
    I'm IN!!
    Love projects like this Ray. Put a set of AllBalls tapered bearings in the steeringhead. Very cheap on Ebay. Got a set for $34 for my project.
    Nice work... If you get bored, I'm going thru a '78 TT500 and could use some help removing "Ick"!
    #48
  9. craydds

    craydds Long timer

    Joined:
    Aug 3, 2010
    Oddometer:
    1,176
    Location:
    Las Cruces, NM
    I may go ahead and get all new bearings - for the wheels, too! Sounds like the tapered roller bearings would be better in the steering head. Good luck with your TT, I like those bikes. I have spent countless hour cleaning up all the old "ick". Wish I could take it somewhere and have it all blasted away. There is a wet soda blasting media that seems like it would work well.
    #49
  10. craydds

    craydds Long timer

    Joined:
    Aug 3, 2010
    Oddometer:
    1,176
    Location:
    Las Cruces, NM
    Valleyrider, I dig your photos on flickr. Awesome pics of you sliding sideways around the track! Me and my boys are going to do the American Supercamp in June; http://www.americansupercamp.com/ . It will be great training for my boys and hopefully help me get back in the groove.
    #50
  11. Valleyrider

    Valleyrider I Survived The '60s

    Joined:
    Apr 12, 2007
    Oddometer:
    1,896
    Location:
    Idaho Panhandler
    Thanks Ray!
    I'm having fun getting the TT ready for the upcoming season.
    Just a tease of what I have had to deal with...

    http://www.flickr.com/photos/91461608@N05/

    [​IMG]
    #51
  12. craydds

    craydds Long timer

    Joined:
    Aug 3, 2010
    Oddometer:
    1,176
    Location:
    Las Cruces, NM
    #52
  13. craydds

    craydds Long timer

    Joined:
    Aug 3, 2010
    Oddometer:
    1,176
    Location:
    Las Cruces, NM
    I thought I might leave that swingarm bolt alone, but I could not. Time for the jack hammer:
    [​IMG]

    Lots of penetrating oil, spun the bolt with my air impact driver, and knocked that bolt out with the jack hammer:
    [​IMG]

    Time to place an order with All Balls for the swingarm bearing kit:
    [​IMG]
    #53
  14. craydds

    craydds Long timer

    Joined:
    Aug 3, 2010
    Oddometer:
    1,176
    Location:
    Las Cruces, NM
    Good eye, Scooter, it is a Webco head:
    [​IMG]
    #54
  15. Scootern29

    Scootern29 Been here awhile

    Joined:
    Sep 4, 2012
    Oddometer:
    795
    Location:
    In the hot, hot, dezert
    That head alone is worth some serious $$$. I like your build :clap. I am plugging along with mine.
    #55
  16. Scootern29

    Scootern29 Been here awhile

    Joined:
    Sep 4, 2012
    Oddometer:
    795
    Location:
    In the hot, hot, dezert
    I like the jackhammer trick to the swingarm bolt. Pretty ingenious. :thumb
    #56
  17. craydds

    craydds Long timer

    Joined:
    Aug 3, 2010
    Oddometer:
    1,176
    Location:
    Las Cruces, NM
    Worked like a charm. Got that old rusted bolt out. Previously I beat on it HARD with a hammer and it would not budge. Tore up the threads a bit - will need to run a die over the threads. Bolt is out and polished up, need to run down to the bolt store and get a die and a new nut.
    #57
  18. craydds

    craydds Long timer

    Joined:
    Aug 3, 2010
    Oddometer:
    1,176
    Location:
    Las Cruces, NM
    Anything you want to know about YZ400's, go look at Scootern29's thread. Anyway, forks disassembled and cleaned up, time for new forks seals:
    [​IMG]

    Little heat, light coat of grease on 'em, rop those seals right in:
    [​IMG]

    This is a Yamaha factory race team seal driver:
    [​IMG]

    Seals in:
    [​IMG]

    Dust seals on, forks reassembled, ready to mount:
    [​IMG]
    #58
  19. craydds

    craydds Long timer

    Joined:
    Aug 3, 2010
    Oddometer:
    1,176
    Location:
    Las Cruces, NM
    Old bearings bashed out, new ones should arrive tomorrow:
    [​IMG]
    #59
  20. Scootern29

    Scootern29 Been here awhile

    Joined:
    Sep 4, 2012
    Oddometer:
    795
    Location:
    In the hot, hot, dezert
    Hey Ray, maybe it's the photo.....but the fork tube looks bent in that one pic fo the forks disassembled. I hope not. And BTW I don't know that much about YZ400's. Only a small amount.
    #60