Project 1976 Yamaha YZ400

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

  1. craydds

    craydds Long timer

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    Yes, Vintagespoke, on eBay. Pics later.
    #81
  2. dannyb278

    dannyb278 Adventurer

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    Keep up the good work! I restored a 1976 yamaha IT400 two years ago. Very similar to the YZ400. Tuned right the things can go like a bat out of hell on the straights and climb up a wall if necessary. Just dont try to turn.:wink:

    Are you having any trouble finding parts?

    There is a shop called Yamaha Speed and Sport. i believe they are out of Pennsylvania. Have most anyting for vintage yamahas. Also, Yamaha has a online data base with parts numbers and component breakdowns.

    Cant link them now, but if you need the links, let me know.
    #82
  3. craydds

    craydds Long timer

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    Been able to find most everything I need so far. The bike was almost totally complete and unmolested, hadn't really been trashed as is the case with so many old dirt bikes. Seems like it had been left outside in the weather for too many years, but down here in the desert at least it is dry and fairly kind to machinery.
    Bike is starting to come back together... slowly and carefully.
    Thanks for the tips!
    #83
  4. craydds

    craydds Long timer

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    I have restored several old motorcycles, pickups, Jeeps, VW Bugs, Camaros, etc. Sold my '83 RM250, still kicking myself. Always set them up to RUN. No trailer queens here. Going to RIDE this YZ and crash it. No powder coating for me, I paint with rattle can, that way I can give it a shot of paint after I scratch it up. :lol3
    (thanks for the tips on a puller)
    #84
  5. Valleyrider

    Valleyrider I Survived The '60s

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    Yo se` Rattle Can...

    My TT500 project is a real rust rat. I won't worry about racing it.
    I went a little overboard with my '68 DT1. Can't bring myself to put it on the track again.
    #85
  6. craydds

    craydds Long timer

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    Keep that one on the mantle above the fireplace.
    #86
  7. craydds

    craydds Long timer

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    Rattle can esta muy bien.
    #87
  8. craydds

    craydds Long timer

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    before:
    [​IMG]

    after:
    [​IMG]

    Forks are done. Filled with 415 cc of 10 wt. fork oil according to service manual specs, seems like a lot. May draw some out, service manual said measure 163 mm to oil - range of 146 to 195 mm - might take it down to 150 mm. Easy to add more if needed. Fork boots from vintagespoke:
    [​IMG]
    #88
  9. craydds

    craydds Long timer

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    Old:
    [​IMG]

    Zero damping:
    [​IMG]

    Back from Race Tech:
    [​IMG]

    A trick I learned from Scootern29:
    [​IMG]

    No swingarm yet, but the monoshock is ready:
    [​IMG]

    New:
    [​IMG]
    #89
  10. craydds

    craydds Long timer

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    It's fun seeing the big stuff go back together, might start to look like a dirt bike. But so much time is spent doing little things:
    [​IMG]

    Little details, lots of work:
    [​IMG]

    Not too exciting, but necessary:
    [​IMG]

    Now, if I can get that flywheel off...
    #90
  11. Valleyrider

    Valleyrider I Survived The '60s

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    You having any luck with the flywheel Ray??
    #91
  12. craydds

    craydds Long timer

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    Yes, I am having BAD luck. :huh Got a flywheel puller, tried every trick in the book, no luck. Time to find a puller that will grab the flywheel externally. May try O'Reilly Auto this evening, see what types of pullers they have. Bought another flywheel from eBay, has threads in good condition, should arrive this week. That way if I totally destroy existing flywheel I'll have a replacement.
    #92
  13. Valleyrider

    Valleyrider I Survived The '60s

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    When you get the puller, try applying some heat around the area where the threads should be. Hope things go better!
    #93
  14. heliyardsale

    heliyardsale Always looking for Dirt!

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    What did race tech charge for the rebuild?
    #94
  15. craydds

    craydds Long timer

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    The total was $202; $177 for the rebuild plus $25 for their shipping charge. It cost me $28 to ship it to Race Tech so actually my total cost was around $230 for my BRAND NEW rebuilt shock.
    #95
  16. craydds

    craydds Long timer

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    Got swingarm installed with new All Balls bearings/seals/thrust washers, new swingarm "thrust cover" and chain guard to replace the chewed-up piece:
    [​IMG]

    Bet that the NEW monoshock will work well:
    [​IMG]
    #96
  17. craydds

    craydds Long timer

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    Put puller in freezer, heated flywheel. Tapped puller into flywheel (no threads), trying to get a friction fit:
    [​IMG]

    Heated everything up to smoking HOT, flywheel won't budge. Puller slips out of flywheel:
    [​IMG]

    Next attempt - going to O'Reilly's for a puller that will grab the slots in the flywheel or grab the outside edges. Cutting torch... anybody?
    #97
  18. craydds

    craydds Long timer

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    Sanded off old flat black paint that PO must have sprayed on. Sanded down through a red primer down to the original yellow. Tank is pretty well beat up, will likely strip it and attempt to do some metal work:
    [​IMG]
    #98
  19. Scootern29

    Scootern29 Long timer

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    Here's a little tip for ya Ray. Loosen up the monoshock so you can move it around before you install the pipe. :wink:
    #99
  20. craydds

    craydds Long timer

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    Cool! Thanks, Scooter!!