Maybe even slower progress

Project is slowing down. Other things and work has kept me busy.
Anyway, assembled wheels, new brakes, chains and chain guide.

Chain line is off maybe a 5mm and I’m still thinking should I do something about it. I think it’s because rear wheel hub isn’t original. Wheel would line up if I made new spacers. I’m just not sure if 5mm is that big of a deal..
Exhaust is still waiting finishing. One of the heat shields fasteners needs to be welded back, all the welds need to be grinded smooth and it needs to be painted. Rear shock extender is also unfinished.

But it will get done eventually. Though my son started to ask when he is going to get the bike back..

Slow progress..

It’s been slow week with the project but I cleaned and painted the wheels, fixed wiring and continued fixing exhaust. Rear shock and exhaust needs still modification but everything else is just waiting assembly.

Homemade HiPo part and exhaust fitting

Didn’t get too much done today, but I did make cover for removed oil pump from carbon fiber. Yes, real carbon fiber! I don’t think that many people have carbon fibre parts in their PW80 🙂 Also installed electronics back to frame, painted the rear shock and spring and fitted the handlebar. Of course I had wrong size nuts for it.. Exhaust was test fitted. It needs a bit modifications because silencer isn’t original and somebody has modified end of the exhaust. I don’t have a clue how to modify exhaust but luckily my friends will help on that. I also changed exhaust’s normal M8 bolts to studs.

Kickstart caused problems and assembly continues

Cylinder and cylinder head was next on the list. Unfortunately I didn’t take before and after pictures from the cylinder. My friend modified cylinder ports a bit and it looked pretty nice. Can’t wait to see how it runs.

I changed oils and oil seals for front shocks few months ago so I just cleaned and painted them before install. Old footrest was bended and welded poorly so I ordered new original with kickstarter, side stand and few other parts from Yamaha. Foot pegs I ordered earlier from Ebay.

Then the kickstarter. It was working fine when I tested it without clutch cover. But with cover, spring didn’t return and kickstarter was left down. So I took off the cover and of course ruined the seal. I installed the starter shaft few times and it didn’t return properly. Finally I figured out how to twist spring so that there was enough tension and starter returned also with cover on..

Engine fitted in the frame

Engine found its place. No big issues here. Just had to be careful not to scratch new paint.

Only thing was that I forgot to put flywheel in place before cover.. And I did it twice! You shouldn’t work tired..

Assembling the frame

Now the fun starts! Putting everything back together with clean parts. I Started with frame, rear arm and triple trees. Steering bearings were replaced earlier so I just cleaned and greassed them.

Notice Yamaha OEM part bags 🙂

Painted engine

After putting engine back together, engine was cleaned, primed and painted just like all the other parts.

I used temporary screws which I changed to allen bolts after painting.

Assembling the engine

It was time to put the engine back together. Crankcases were blasted and washed and other parts were cleaned with brake cleaner. Threads in crankcase were also cleaned with a thread tap. Installed new crank bearings and seals and used new allen bolts to put crankcase together.

I haven’t assembled too many gearboxes before so it took a while figure out everything. But I think I managed, at least engine is turning and there is three gears. Biggest problem was to assemble kick starter but more about it later..

Painted parts

After blasting, parts were cleaned, primed and painted. I used spray cans although I could have used spray gun also. But we had cans around so..

Sandblasting

Next step was to sandblast (actually glass blast) all the parts. Pretty easy and neat with blasting cabinet. Needs large compressor though. Some day I will have my own garage with blasting cabinet..

Here is some parts blasted