Yet Another 76 YZ400 Project Build

Discussion in '2 smokers' started by Scootern29, Mar 18, 2013.

  1. Scootern29

    Scootern29 Been here awhile

    Joined:
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    Oddometer:
    752
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    In the hot, hot, dezert

    These forks aren't anything different really. They have a snap ring and a spacer/washer on top of the seals. I had to drill a small hole in the washer and put in a small screw to pry it out. It was stuck from all the years of neglect. Send me a few bucks and I can send you the original works drawing of the seal installation tool. You will have to burn it when done though. Don't want that in the wrong hands. :rofl
    #21
  2. craydds

    craydds Long timer

    Joined:
    Aug 3, 2010
    Oddometer:
    1,175
    Location:
    Las Cruces, NM
    Nice fork boots. I need new ones, too. NLA from Yamaha, but I suppose any ol' boot will work - fork tubes are 36 mm and the upper end of the sliders are 55.5 mm, so I'll see what I can find.
    #22
  3. Scootern29

    Scootern29 Been here awhile

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    I actually was in a hurry and bought these from DC Plastics. They are generic Daystars. I really don't like them. I found a set on Thevintagespoke.com. They are for TT500's and they are the same as the 400C and look correct. They are like $39. I more than likely will swap mine out.
    #23
  4. craydds

    craydds Long timer

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    Oddometer:
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    Location:
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    Nice seat and rear fender. My seat is okay, looks like it has been re-upholstered, not too bad looking. I had a guy in town do the seat on my KLX300 and he did a fantastic job.
    I want new plastics. Saw a set on ebay for $180, maybe I'll get 'em. I will check DC Plastics, too. Keep up the good work!
    #24
  5. Scootern29

    Scootern29 Been here awhile

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    My next order of business was..........I am not sure, so I worked on the mud flap for under the seat. None are available from Yamaha. I scoured the interweb and found a couple of pictures that kinda showed what it looked like. I had the mounting hardware and cleaned them up. I used some old innertube that I think will work. If not I will get a bigger piece.

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    When I took the bike apart I found this problem with the pipe.

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    I took a long bolt and stuffed it in the nut to pull it out to tack weld.

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    All welded up and ready to go.

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    #25
  6. Scootern29

    Scootern29 Been here awhile

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    I hadn't messed with the rear wheel yet so out came the soda blaster again.

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    While I was wandering aimlessly around the garage I picked up the front brake cable guide that mount on the bar clamps. It was broken. So back to welding. I forgot this was spring steel and it was pretty exciting when I arc's it up. Massive flash. But it worked. All finished.

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    #26
  7. Scootern29

    Scootern29 Been here awhile

    Joined:
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    In the hot, hot, dezert
    The levers on the bike were beyond repair IMO so I bought a set off ebay. I picked up the correct throttle from a bud of mine in Sandy Eggo. They had a whirlpool on it and that is not what I want for this build.

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    Bars and controls mounted. Believe it or not........the bars are orignal and not bent.

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    #27
  8. Scootern29

    Scootern29 Been here awhile

    Joined:
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    Location:
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    Next I cleaned up the air box and the rear backing plate. They were in real good conditon.

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    Now the fun part. I thought I would just slap the airbox in no problem. I had to take the shock off the rear wheel and drop the swing arm to get it in.

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    I am only doing a MOCK UP, so I'm thinkin it's all good from here on out. Piece of cake. Boy was I wrong. The filter cage is very stout. The filter is very stout. The cages are tapered as well as the filters. I get them on finally. Thank the Lord I dont' have oil on them. It would not be pretty.

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    The real fun begins. This should be easy put the rod into the side cover slide it through, put on the other filter and cover and you are good to go. WRONG EM BOYO (from a Clash song). The air box is tapered on both sides, and the clamping rod is bent on both ends to accomadate the taper. So here I am trying to hold one side of the filters with my left hand, trying to line up the right side with my right hand, and because I can't see things as well any more I have a flashlight stuffed in my mouth looking upside down to line it all up while DROOOLING ALL OVER MYSELF. Boy is this fun. I finally get it installed. I am worn out.

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    #28
  9. hoodellyhoo

    hoodellyhoo Dummy

    Joined:
    Jan 15, 2010
    Oddometer:
    232
    Location:
    Neenah, WI
    Not at all!!:clap

    For the most part I have no interest in owning an off-road bike but I am inexpicably drawn to the old yamaha DT's and YZ's. They just look so.....right.
    #29
  10. Scootern29

    Scootern29 Been here awhile

    Joined:
    Sep 4, 2012
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    Location:
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    I was gonna post more today...........but...........I got sidetracked and had to buy this bike.

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    #30
  11. craydds

    craydds Long timer

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    Oddometer:
    1,175
    Location:
    Las Cruces, NM
    Sweet machine! What model, year, cc's, etc.?
    #31
  12. Scootern29

    Scootern29 Been here awhile

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    1974 TY 250A. First year of the trials bikes. I am sure it will run and will do another thread if I don't sell it.
    #32
  13. Scootern29

    Scootern29 Been here awhile

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    Location:
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    I spent some time soda blasting some of the aluminum parts as well as some of the other hardware.

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    I took my little palm sander to the brake stay arm to take some of the scratches out of it.

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    Took the backing plate apart as it was pretty dirty.

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    Got it all painted up and installed the rear wheel into the swing arm.

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    #33
  14. Scootern29

    Scootern29 Been here awhile

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    Next up is working on the motor. I will polish the rims at a later date. I had to soak the flywheel nut for quite a few days as it was pretty nasty. I needed to wait a few days for a new puller as the one I bought a couple of months ago wouldn't fit this bike.

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    Got the flywheel off and yep it is pretty nasty. :puke1 The bike ran like this which to me is pretty amazing being it has an electronic ignition.

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    The stator is equally as nasty. :puke1 :puke1

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    #34
  15. Scootern29

    Scootern29 Been here awhile

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    Location:
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    I spent a few hours cleaning up the ignition parts. I took some real fine sand paper and cleaned off the magnets real good and decided to you may have guessed..........try the soda blaster on the flywheel. It worked real well. I then took it too my wire wheel to clean up what wouldn't come off. It looks pretty good.

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    I figured I might as well try the soda on the stator itself as what the hell, it ran before, so what can I really mess up. It took off alot of it and I ended up taking all of the old silicone off and replaceing it with new and had to repair the wiring in a couple of places. For some reason the pictures make it still look tarnished but it must be shadows as it is real clean.

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    #35
  16. Scootern29

    Scootern29 Been here awhile

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    Pulled of the head and it looks pretty good down the bore.

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    Taking off the cylinder.

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    May need a new piston or just clean up and new rings. We shall see.

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    #36
  17. Scootern29

    Scootern29 Been here awhile

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    So now I'm at this point and ready to start taking the low end apart. This should be fun as I haven't done one in quite awhile.

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    Got it to this stage pretty quickly.

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    I didn't have a case splitter so I had to make one. I didn't get any pics of it during the process. It was a chore to get the cases apart. Once I got them apart the crank came out pretty easy. A little heat from a heat gun and a rubber mallet did the trick.

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    The crank is in exceptional condition. The bike I don't think was really rode that much. Everything is tight. I will clean up the stator side of the crank before re-installation.

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    #37
  18. Scootern29

    Scootern29 Been here awhile

    Joined:
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    752
    Location:
    In the hot, hot, dezert
    I procrastinated a couple of weeks and finally ordered up seals and bearings and they arrived.

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    I contemplated using the old bearings but I am this far and ordered them up to. In the meantime here's the cases I am going to use.

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    #38
  19. Scootern29

    Scootern29 Been here awhile

    Joined:
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    752
    Location:
    In the hot, hot, dezert
    I got a little side tracked and had to rebuild about 8 sets of Curnutts for customers so I didn't get much done for a week or so.


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    A couple of the guys in my club the Hilltoppers needed some work done on their suspensions. I did a set of forks and built some shocks for this guy, Rich. 70 years old and just did his first race in 40 years and finished. His son is an inmate on here. Drunclewill.


    Rich then at Deadman's Point here is socal.


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    Rich now a month ago.

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    Set up a pair for Ronnie, he is going for the #1 plate in D37 Classic division. He is going almost as fast as his modern bike on this thing. He is the taller one.

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    #39
  20. Scootern29

    Scootern29 Been here awhile

    Joined:
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    Oddometer:
    752
    Location:
    In the hot, hot, dezert
    The week before last I soda blasted the cases and started to install the bearings.

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    After putting the main bearings into my deep freezer I used this old dental press that I acquired to install them. I use this press for putting in shock seals. This thing I think is from the late 50's early 60's. If anyone knows, let me know. It does a sweet job.

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    #40