Project 1976 Yamaha YZ400

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

  1. Foot dragger

    Foot dragger singletracker

    Joined:
    Dec 27, 2006
    Oddometer:
    13,837
    Location:
    chico,just below rag dump(nor-cal)
    I was checking that TT500 tank for leaks with air pressure,I accidently gave it too much of an air squirt and the whole tank spread and cracked in a second,useless now.
    I would be careful with it,they want a couple hundred for an average one on ebay. If it was steel a hot-stick gun would be the ticket for pulling dents.
  2. craydds

    craydds Long timer

    Joined:
    Aug 3, 2010
    Oddometer:
    1,176
    Location:
    Las Cruces, NM
    Well, I bought a tank on eBay - http://www.ebay.com/itm/1976-Yamaha...50-Aluminum-gas-tank-straight-Nice-AHRMA-/200 - don't want to destroy my old tank, but I will have a back up. Maybe I should just sand my old tank, paint it and run it as is. I diid find a tank from Clarke - http://clarkemfg.com/yz250125-7476-stock-capacity-p-244.html - might work???
  3. craydds

    craydds Long timer

    Joined:
    Aug 3, 2010
    Oddometer:
    1,176
    Location:
    Las Cruces, NM
  4. craydds

    craydds Long timer

    Joined:
    Aug 3, 2010
    Oddometer:
    1,176
    Location:
    Las Cruces, NM
    Went to O'Reilly's:
    [​IMG]

    Puller:
    [​IMG]

    Forks were too long (or the bolt was too short, take your pick):
    [​IMG]

    No threads on the flywheel, all rusted out. Yes, that is JB Weld, tried to pull the flywheel but no luck with the old puller:
    [​IMG]

    Wedged forks into slots so they wouldn't slip out, used the old puller center piece to center the steering wheel puller bolt, heated the flywheel to SMOKING HOT:

    [​IMG]

    A lot of torque on the puller, a few sharp blows with a hammer, and the flywheel popped loose:
    [​IMG]
  5. craydds

    craydds Long timer

    Joined:
    Aug 3, 2010
    Oddometer:
    1,176
    Location:
    Las Cruces, NM
    The flywheel was rusted onto the crank shaft, nasty:
    [​IMG]

    I hate dirt and rust:
    [​IMG]

    Sad:
    [​IMG]

    When I first pulled of the external magneto cover, the interior was full of water and dirt:
    [​IMG]

    Knew I had to get that flywheel off and clean things up:
    [​IMG]

    Better now:
    [​IMG]

    Going to put this old flywheel back on, but the threads on the other side are shot. I know now that I can pull if off again whenever necessary, will apply a good dose of anti-sieze when I put it back on:
    [​IMG]

    Ordered an new woodruf key from my local Yamaha shop, should arrive next week. Will lap that shaft and the flywheel internal bore so they are shiny and smooth, and apply a coat of anti-sieze:
    [​IMG]
  6. Valleyrider

    Valleyrider I Survived The '60s

    Joined:
    Apr 12, 2007
    Oddometer:
    1,896
    Location:
    Idaho Panhandler
    9.9 You lost a tenth of a point for lack of description on the cleaning process! Nice job.
  7. craydds

    craydds Long timer

    Joined:
    Aug 3, 2010
    Oddometer:
    1,176
    Location:
    Las Cruces, NM
    :rofl
    Lots of Berryman's carb cleaner, Grimeout detergent, scrubbing, phosphotic acid ( "naval jelly" ), wire brushing, and SODA BLASTING. and I am still NOT done...
    Been working on wheels today, more to come.
  8. Valleyrider

    Valleyrider I Survived The '60s

    Joined:
    Apr 12, 2007
    Oddometer:
    1,896
    Location:
    Idaho Panhandler
    Nice job!!
    Racing the TT for the first time tomorrow... weather permitting!!
  9. Scootern29

    Scootern29 Been here awhile

    Joined:
    Sep 4, 2012
    Oddometer:
    789
    Location:
    In the hot, hot, dezert
    Show the wheels my man. Mine are a little tarnished, and I don't think I will polish them out.
  10. craydds

    craydds Long timer

    Joined:
    Aug 3, 2010
    Oddometer:
    1,176
    Location:
    Las Cruces, NM
    Cleaning up the old rear:
    [​IMG]

    Old front:
    [​IMG]

    Shiny front:
    [​IMG]

    Clean rear brake:
    [​IMG]

    New tires:
    [​IMG]
  11. craydds

    craydds Long timer

    Joined:
    Aug 3, 2010
    Oddometer:
    1,176
    Location:
    Las Cruces, NM
    out of sequence, but this is the old dirty rear wheel:
    [​IMG]

    Close up, rear, and the front was in the same dirty state:
    [​IMG]

    Got new All Balls wheel bearings/seals and new tires. More to come...
  12. Scootern29

    Scootern29 Been here awhile

    Joined:
    Sep 4, 2012
    Oddometer:
    789
    Location:
    In the hot, hot, dezert
    Lookin good. I have been waiting for you to post. I thought you got lost or something?

    Scott
  13. craydds

    craydds Long timer

    Joined:
    Aug 3, 2010
    Oddometer:
    1,176
    Location:
    Las Cruces, NM
    Several projects going on, been working on my son's XR200. Slowly working on the YZ, making some pictures. Then, it's hard to find time to get a few posted here. I am going to quit eating, sleeping, etc., big waste of time, could be working on motorsickles.
    :tough
  14. craydds

    craydds Long timer

    Joined:
    Aug 3, 2010
    Oddometer:
    1,176
    Location:
    Las Cruces, NM
    Spoke nipples were RUSTY. Cleaned them up as best I could. Notice crack in wheel, had a few cracks in both wheels. I so much want to send them to Woody's for new rims and spokes! But, it is cost prohibitive for now, just going to run them as is. May be later on I will pick up a set of wheels off eBay and get them rebuilt:
    [​IMG]

    New front tire:
    [​IMG]

    New rear rubber:
    [​IMG]

    High tech motorcycle lift:
    [​IMG]

    Progress!
    [​IMG]

    Ready to MOTO:
    [​IMG]

    Rolling chasis. Ready for a Briggs & Statton lawn mower engine:
    [​IMG]
  15. MartinPetren

    MartinPetren Swedish Adventurer

    Joined:
    Sep 2, 2009
    Oddometer:
    372
    Location:
    Gothenburg or Uppsala
    It's coming out really nice! Hope you get to ride it soon :clap
  16. tkitna

    tkitna Long timer

    Joined:
    Nov 3, 2007
    Oddometer:
    6,392
    Location:
    West Virginia
    Cripes another YZ 400 build thread. Subscribed to this one too.
  17. dtysdalx2

    dtysdalx2 PITA but useful

    Joined:
    Aug 1, 2004
    Oddometer:
    14,800
    Location:
    Moneyapolis, MN
    :lol3

    These old MX bikes are my favorite! Bring em all! :clap
  18. Scootern29

    Scootern29 Been here awhile

    Joined:
    Sep 4, 2012
    Oddometer:
    789
    Location:
    In the hot, hot, dezert
    This is coming out real good. Keep it up. :clap
  19. craydds

    craydds Long timer

    Joined:
    Aug 3, 2010
    Oddometer:
    1,176
    Location:
    Las Cruces, NM
    When I bought the bike, this was the funky kick stand:
    [​IMG]

    Got an original kick stand on eBay, painted it, got a new spring, too:
    [​IMG]

    This tab was welded on by a gorilla:
    [​IMG]

    Kick stand won't fit over the tab:
    [​IMG]

    Angle grinder to the rescue:
    [​IMG]
  20. craydds

    craydds Long timer

    Joined:
    Aug 3, 2010
    Oddometer:
    1,176
    Location:
    Las Cruces, NM
    Rear:
    [​IMG]

    Front::
    [​IMG]

    Parts:
    [​IMG]

    More parts:
    [​IMG]

    Motor scooter. Still have lots of work to do, might get something done over this long weekend:
    [​IMG]