'73 Yamaha Ag 100 project

[Haysie]

Hey guys,

Been lurking long enough and decided to show off my current project.

I got inspired off another website to turn an ordinary Ag bike into a something different.

Picked this little gem up about a year ago, it was pretty beat, but all there. The plan at that stage was to restore and bring her back to her former glory. After doing some research and seeing what a few guys have been doing with their DT's, LT's and CT's the plan was changed. All good plans are a basis for change.....right?

Stripped her down and cleaned up the frame as best as I could. Didn't matter too much as she was going to be media blasted and powdercoated.

Got all the smalls nickel plated



Frame etc, returned back after powder coating.

[cyclegod]

Nice start to it, if you want to convert to 12V then fit...

http://www.powerdynamo.biz/eng/systems/7038/7038main.htm

a lot of other RS100/125 stuff will fit too

[Haysie]

Thanks, I'm going to remove the lighting coil and only run the ignition coil. It is not going to have any other electrical add-ons apart from a kill switch. Wouldn't mind getting rid of the points. When I tried to start the bike when I got it home, I couldn't get a spark. Tried setting the points to what the manual stated, but no luck. Thought I might cure it by cleaning everything. I've got a new coil, spark plug and points to go in.

[Haysie]

Got a bit more done. Had pulled the engine apart, put new bearings and seals in it. The bore looked pretty good so I only gave it a light hone. The piston was fine so I got some new rings. Painted her up and installed it in the frame.



Steering was next and then the handlebars. Not sure if I like the hand grips, but they will do for now.

[Rossvickicampbell]

looking good - I like watching rebuilds.

[mick25]

A blast from the past ag bike 
I had half a dozen of these growing up in nz ,
 I had the yellow models and a few red models with the larger tank ,
I Locked up two gear boxes over the years , I rember my old man saying to me have you checked the oil in the gear box I said yes it's full  I fulled it to the top until
It was flowing out I was only 13 or so 
I did have a ride on a orange ag 175 was a power house compared to the 100
The ag 100 were like coach roaches in nz in the eighties .
Good to see you are getting one back to life .
That's right they had a twin spark plug head two that came in handy when one plugged died 

[yamaico]

Thanks, I'm going to remove the lighting coil and only run the ignition coil. It is not going to have any other electrical add-ons apart from a kill switch. Wouldn't mind getting rid of the points. When I tried to start the bike when I got it home, I couldn't get a spark. Tried setting the points to what the manual stated, but no luck. Thought I might cure it by cleaning everything. I've got a new coil, spark plug and points to go in.

Nice job Haysie, keep the photos coming.
The ignition on those little Yammies is pretty bulletproof. Make sure that the magneto flywheel key is intact, the magnets are clean and rust free, all the earths are good, particularly where the ignition coil mounts to the frame, and the points are clean. A new condenser would be a good idea if you haven't already got one. If you still don't have any spark check the pickup coil resistance which should be, from memory, around 10 ohms, and the source coil resistance which should be around 300 ohms.
Pete.

[Haysie]

Thanks for the support. I am hoping that after everything has been cleaned up that the spark will be there. Yes the little Ag bike has been a solid work.....pony. The spare spark plug hole just has the screw in plug, but might go for another spark plug later.
I do my own media blasting and powdercoating of smalls. I am only using a household oven, so whatever I can fit into it I do myself.
Even though I am not going to run a battery, I powdercoated the battery carrier and put it back on.... might also double as a handy tool box, although I do have the original tool box for it.... might do that next. I also powdercoated the front mudguard stay as I am going for the high mudguard look. The rear hub cleaned up really well, can't wait for the new spokes to arrive to finish off the rims.

[yamaico]

Wow, nice carpeted workshop. You must have a very understanding wife/girlfriend/landlord/mother/flatmate....

[Haysie]

Yes, she is very understanding. It is in a room of our house that we (the rest of the family) doesn't use much! It has no fluids in it and shouldn't leak at all!
Bit more work done, got the exhaust, carb, original air filter and coil on. Fitted the forks, although they are a bit pitted, they are still in pretty good nick. Might try and find some gaiters somewhere to cover them up.

[Haysie]

Well thanks to Easter got a fair bit done to the bike. The spokes arrived and I was able to respoke the rims. Mounted the tyres on to the rims and put the brand new shocks on. Finally after about 6 months the bike is back on to its wheels again.



Yeah, I know the front brake arm is on the wrong way. My daughter (8 years old) was trying to help me.

[Haysie]

So, now that I have got her on her wheels, I kicked her over to see if there was a spark. Nothing. Spent a fair bit of time setting the points as per the manual and various recommendations from this site and others. I have a brand new coil, new points, new spark plug and checked the wiring for continuity etc. All seems fine. I have also checked the ignition coil and condenser with a multimeter and within the parameters set out in the manual. Still I get no spark.

Any thoughts?

[yamaico]

So, now that I have got her on her wheels, I kicked her over to see if there was a spark. Nothing. Spent a fair bit of time setting the points as per the manual and various recommendations from this site and others. I have a brand new coil, new points, new spark plug and checked the wiring for continuity etc. All seems fine. I have also checked the ignition coil and condenser with a multimeter and within the parameters set out in the manual. Still I get no spark.

Any thoughts?

Check the earths, particularly the coil to the frame and the motor to the frame. Disconnect everything and connect a wire from the black (or maybe black/white) wire coming out of the magneto and connect the other end straight to the coil and try that. Is the new coil the correct one (AC) for the bike?
If you still have no spark beg, borrow or buy an old peak meter, set it to AC volts and connect it to the points wire and kick the bike over without the plug in. The meter needle should deflect when you kick it.

[Haysie]

Haven't posted for some time now, so here is an update.

Finally sorted out the issue with no spark.... bought another coil (2nd hand) but connected it up and got a nice blue spark! Cleaned the coil up and reconnected it and made sure that the spark was still there.... happy days!

Got the tank and mudguards back from my son, he is a automotive spray painter and he did an awesome job. Exactly what I wanted and a fantastic finish. Mounted the tank and guards on just to see what it looked like...
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Took a while to drill holes into the mudguards to fit the permanently, but bit the bullet and measured a hundred times and drilled once!!!
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While the seat was with my upholsterer.
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I had a café racer style seat, which I had bought for another project, and put it on the bike to see what it looked like...
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It looks okay, but I would have to drill and weld brackets on, and it is a bit late to do that. Maybe on the next project!

Anyway, got the seat back from the upholsterer and fitted it straight away. Seat pan cracks were welded up and new foam. Not bad at all.

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Looks the part, but I think I prefer the other seat!

The area where the original bash plate had been located had been bugging me for some time and it looks like it needs something. The old bash plate was pretty well bashed up, so I didn't want to put it back on...

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So I got a piece of 3mm aluminium plate and had it rolled to the contour of the frame, cleaned it up and bolted it on, cleans the area up, but not sure if it needs holes or not.

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Every VMX needs a number plate, cut out an oval shape onto 2mm aluminium and mounted it on the front forks.

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It needs painting, but I will wait for better weather before I can paint it. Way too cold at the moment.

Well it is just about complete. Haven't put any fuel or oils in it yet. I know it has spark and that it will start if I put fuel in it. Going to put fork oil in this weekend but that is about it. I have another stator plate to put on. The other one suffered some damage while I was figuring out the spark issue. Need to wait for some decent weather so that I can paint it.
Now for another project.....

[BSA-B5]

It would make a nice bucket racer in pre 75.