OzVMX Forum
Marque Remarks => Yamaha => Topic started by: Trokel510 on December 16, 2016, 09:54:26 PM
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A while back I purchased this little project, not because i needed another bike but because I like IT's and it seemed like too good a deal to pass up.
(http://i613.photobucket.com/albums/tt213/trokel_photos/Motorbike%20Pics/Vinduro%20stuff/DSCN5239_zps3krvsnzm.jpg)
But unfortunately it has been sitting around ever since as I just haven't been able to source some of the parts i needed at the right price that is up until now as last weekend I picked up this one also.
(http://i613.photobucket.com/albums/tt213/trokel_photos/Motorbike%20Pics/Vinduro%20stuff/IT250H%201_zpsfmp40iv8.jpg)
So now with a bit of luck I hopefully have everything that I need. Currently I have stripped them both down to only a frame in order to compare the 2 and pick the best one then start the rebuild from there. So Will keep you updated on the progress with more Pics to come
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away we go 8)
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Good luck with the restoration Troy. Looking forward to more pics.
Cheers Chippy.
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Good luck with the restoration Troy. Looking forward to more pics.
Cheers Chippy.
Thanks.
My intent is for this to become my main Vinduro bike for the 2017 season so it won't be a showroom resto but I am still planning on turning it into a good looking bike that will hopefully be reliable.
Have had a busy day working on the frame.
Both frames had problems. The one on the left had numerous cracks, holes drilled in it for some reason, a completely mangled rear loop and broken side stand mount. The one on the right had a bodged footpeg, a fair bit of surface rust and some repairs to the rear loop that were pretty rough but overall it was probably the better frame but for some reason I decided to fix the other one. Think I just felt like a challenge.
(http://i613.photobucket.com/albums/tt213/trokel_photos/Motorbike%20Pics/Vinduro%20stuff/DSCN0120_zps4bgthbtx.jpg)
The white tape is marking all the spots that need repairs
(http://i613.photobucket.com/albums/tt213/trokel_photos/Motorbike%20Pics/Vinduro%20stuff/DSCN0121_zpsbv4x9kow.jpg)
The rear loop was un-salvageable so I cut it off and started making a new one which I fitted up over some steel dowel pins for strength before welding into position
(http://i613.photobucket.com/albums/tt213/trokel_photos/Motorbike%20Pics/Vinduro%20stuff/DSCN0124_zpsoaihc86p.jpg)
And after welding up all the other bits I managed to get the first coat of epoxy enamel paint on this afternoon with the second coat to follow tomorrow. This evening seeing as the paint was dry enough I stuck the rear guard on to show how the rear loop came up.
(http://i613.photobucket.com/albums/tt213/trokel_photos/Motorbike%20Pics/Vinduro%20stuff/DSCN0127_zpsgoq5seor.jpg)
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Keep them coming Troy. Chris's fibreglass doesn't happen any longer , so you will have to make do with what you have.
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Fortunately the first bike came with a full set of brand new plastics and I have 3 tanks to choose from so it should scrub up pretty well. Still tossing up what front end to put on it as the first one came with a TT250 disk brake front end and the second looks like it has an IT490 front end with the dual action drum brake. So if anyone has any thoughts on which one to go with and why that would be appreciated.
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good stuff
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go with drum then you can cross the border for a few events. the it dls is a pretty good drum brake
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go with drum then you can cross the border for a few events. the it dls is a pretty good drum brake
I was thinking of trying to get to some veri events next year so does that mean I would have to stay with the drum to be eligible?
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go with drum then you can cross the border for a few events. the it dls is a pretty good drum brake
I was thinking of trying to get to some veri events next year so does that mean I would have to stay with the drum to be eligible?
Fit the disc if it stops better/ more reliably. I don't imagine anyone's going to throw you out over a disc on the front :)
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Fit the disc if it stops better/ more reliably. I don't imagine anyone's going to throw you out over a disc on the front :)
Was just looking through my selection of front wheels and at this stage most of the drum brake ones aren't real flash so i think it will get the disk front end for the time being.
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I have decided that I will try and make this build thread as informative as possible in an effort to assist others who are new to this type of thing and are thinking of taking on a project. So even though this will seem like pretty standard stuff to many of us I still find that I can always learn new tricks and tips from what others do. So with the frame sorted my focus turned to the swing arm and wasn't that a challenge. During disassembly of both bikes i had to remove the swing arm and shock as a complete unit because i couldn't get the shock to swing arm mounting pin out while still in the bike. What I didn't realize was how hard it was still going to be once removed and with better access. So with this in mind I can't stress enough the need for regular maintenance which means applying grease/ anti seize lubrication to all pivot pins as well as bolts that pass through any spacers as part of suspension pivots such as swing arm and linkage bolts and also axles for wheels etc. And note this doesn't just apply to old bikes as often this doesn't happen when new bikes are assembled so if ridden in harsh conditions they can suffer from the same problem even though they are only a few years old. I found this when I tried to remove a swing arm bolt on a 2 year old KLR650. So even though it was so young the bolt had already began to seize in place due to a lack of lubrication when assembled.
Anyway so here is how it went down -
The shock to swing arm pivot pin passes though 2 steel ferrules that are pressed into the alloy swing arm and this is where the problem lies as without any lubrication they rust together and create a very strong bond. On both I heated the alloy and ferrule with map gas to expand it and sprayed the pin with freeze release spray numerous times but it still took an awful lot of force to press the pin out and in both cases the outer ferrule came with it which I then had to remove separately in the press. Also I had to cut the end of one of the pins off as it had already been damaged by someone else trying to get it out.
Anyway here are some pics
Here is the swing arm and pin with ferule still attached.
(http://i613.photobucket.com/albums/tt213/trokel_photos/Motorbike%20Pics/Vinduro%20stuff/DSCN0132_zpsgmldohsz.jpg)
And here is how the swing arm looks now.
(http://i613.photobucket.com/albums/tt213/trokel_photos/Motorbike%20Pics/Vinduro%20stuff/DSCN0133_zpse0e7votg.jpg)
For the finish on the swing arm I started off by trying to cleanup and restore the natural aluminum look but after much work with a wire brush on a drill and sanding with wet and dry I realised that I wasn't going to get the result that I wanted so i decided to paint it just like I have for all the steel ones that I have done. So after preparing it I painted it with a quality etch primer and then over coated with epoxy enamel.
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poor maintenance the curse of the resto :( >:(
fortunately my huskys both had excellent first owners who greased everything (Phew) nothing beats sliding out a well greased swingarm bolt after 20 years or so....makes life very easy
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poor maintenance the curse of the resto :( >:(
fortunately my huskys both had excellent first owners who greased everything (Phew) nothing beats sliding out a well greased swingarm bolt after 20 years or so....makes life very easy
I was very fortunate in that regard with my Husky as well.
A few years ago I did up a couple of old Yamaha AG200's that i bought as wrecks for next to nothing and some people I know couldn't understand why i was putting so much time into them but to me it was good practice. Because they were so cheap I had nothing to loose and they made great platforms for fine tuning my repair skills particularly with how to deal with the problems that come from poor maintenance. I figured if things went wrong it was better to stuff up an AG200 instead of a more valuable bike and as it turns out they both came up really well so we used them to dink the kids around on before they started riding their own bikes then sold them for a profit. :D
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always pays to start with something like that, cant go wrong too much.... ::)
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Other than the public holidays I am working through the Xmas break so don't have a lot of spare time for work on the bike but it is still coming along slowly but surely.
(http://i613.photobucket.com/albums/tt213/trokel_photos/Motorbike%20Pics/Vinduro%20stuff/DSCN0151_zpsotuhtiyv.jpg)
This motor came with the 2nd bike and according to the guy i bought it from it has had all new bearings and seals through the bottom end and also been re sleeved back to standard. Looking in the exhaust port it all looks brand new. One thing I noticed that I thought was a bit strange was that it is running a single ring piston so i was wondering, is that a common thing and are there any benefits?
So after a bit of cosmetic work on the motor here is how it all looks currently.
(http://i613.photobucket.com/albums/tt213/trokel_photos/Motorbike%20Pics/Vinduro%20stuff/DSCN0160_zpslskiik3n.jpg)
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looking the goods ;)
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Single ring piston could be out of a YZ, wouldn't expect it to maintain full compression for as long
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Single ring piston could be out of a YZ, wouldn't expect it to maintain full compression for as long
Yeah sort of figured that, therefore probably not the best choice for an enduro bike which makes me wonder why they are even available like that. Does one ring yield that much better performance in the short term to make the shorter life worth it?
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Troy use a 2 ring Wossner piston in the IT, I used a stainless steel shock pin and furrules from Moto Enduro UK on my IT , keep an look out for shock oil weeping from the shock hose as they are getting old now I had to replace mine recently, Sean at SOS Suspension replaced the hose on my shock.
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the single ring piston is for performance at cost of wear - mx. 2rings support piston for longer bore life = enduro.
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Well all I can say is this bike has been a challenge and taken up huge amounts of my time but finally it looks like things are coming together and with a bit of luck i will kick it in the guts tomorrow and be rewarded with that beautiful 2 stroke sound.
Unfortunately due to being so busy i haven't had the time to do a detailed built update on a regular basis but here is some more pics of how it has progressed.
One of the most time consuming parts has been sorting out the exhaust. From both bikes I bought I had 2 different expansion chambers and mufflers, one of each (muffler/Chamber) seemed original but in poor condition and the other 2 were different and of unknown origin and none of them seemed to match up with the existing mountings.
Here is one of the mufflers
(http://i613.photobucket.com/albums/tt213/trokel_photos/Motorbike%20Pics/Vinduro%20stuff/DSCN0234_zpsicjkh0x5.jpg)
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So I went in search of a new muffler and was thinking of buying a brand new DG but due to the expense as well as the thought that I would probably still have to modify it to match the different expansion chamber I ended up buying this second hand RMX250 muffler on ebay and modifying it to fit but at the same time still had to work out how the new side cover was going to mount up.
(http://i613.photobucket.com/albums/tt213/trokel_photos/Motorbike%20Pics/Vinduro%20stuff/DSCN0272_zpsljkvx8wq.jpg)
(http://i613.photobucket.com/albums/tt213/trokel_photos/Motorbike%20Pics/Vinduro%20stuff/DSCN0284_zpsv1sflb5e.jpg)
(http://i613.photobucket.com/albums/tt213/trokel_photos/DSCN0289_zpsodmgjef4.jpg)
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I new Ride for This Year Vinduro Season Troy ...
You have done a Good job ......
VTR
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I new Ride for This Year Vinduro Season Troy ...
You have done a Good job ......
VTR
Thanks.
Started it up last weekend and it seems to run pretty well and idles nice but haven't had a chance to ride it yet to see if it revs out properly. Also Still lots of little bits and pieces to finish off and have been a bit side tracked working on the XR600 to get it ready for Broadford so it hasn't progressed much since then.
Now for a few more pics ;)
As mentioned earlier the front end i used was from an early TT250 which was wider between the mounting pins on the lower triple clamp.
(http://i613.photobucket.com/albums/tt213/trokel_photos/Motorbike%20Pics/Vinduro%20stuff/DSCN0168_zpsvx52cksl.jpg)
I noticed this was also the case for the later K model front end I had so here is what I did to accommodate the H style headlight surround. .
First I had to remove the original mounting pins which are pressed in. A pair of vice grips and brute force while twisting back and forth worked well here.
(http://i613.photobucket.com/albums/tt213/trokel_photos/DSCN0167_zpshzs5axhi.jpg)
Then I drilled the holes a bit deeper and tapped them with a 6mm thread and made up an alloy plate with stainless bolts fitted to form the new mounting pins and bolted it all into place.
(http://i613.photobucket.com/albums/tt213/trokel_photos/Motorbike%20Pics/Vinduro%20stuff/DSCN0271_zpssab2jxj6.jpg)