Yamaha XS900 Triple Cafe Racer Build......."SHAFTY"

[pugeyed 0]

got the engine back from blasting today, here are some pics.

nice and clean for the rebuild now.........

[dick65 0]

looks like new mark,excellent job m8

[pugeyed 0]

yeah im happy with it dick, slight problem , i forgot to mask off the oil level sight glass, its got a lovely frosted effect now lol

[dick65 0]

@pugeyed wrote:

yeah im happy with it dick, slight problem , i forgot to mask off the oil level sight glass, its got a lovely frosted effect now lol

thats a shame mark,can you get a replacement?

[pugeyed 0]

yeah ill find one from somewhere.
blimey there is alot of grit inside this thing. gonna have to wash these cases out VERY well.

[XS1100 0]

Lol more than very well one grain and its goosed!
can you remove the sight glass from the case?I might have one

[dick65 0]

@XS1100 wrote:

Lol more than very well one grain and its goosed!
can you remove the sight glass from the case?I might have one

gaz's magical shed

[lee1 1]

should get a good finish on that now mark

[pugeyed 0]

i know ive gotta be very very carefull about making sure everything is spotless.

could get the glass out but havnt tried yet.

[XS1100 0]

10/4 I will have look see if I have one.

[pugeyed 0]

you can still get em gaz!
cheers for having a look, mine is deffo goosed!
http://www.cmsnl.com/products/gauge-level_2h71536100/

dont want to come out though seems pretty solid to me, mind you has probably been in there 30 years..

[pugeyed 0]

ok have new clutch friction plates , engine gasket set, and middle gear case gasket on there way!

still need to buy new clutch metal plates but that can wait abit.

[pugeyed 0]

new con rod bearings on there way... still need new crank bearings which im working on....

[Davehutch-hutchs 0]

just read this thread from the start, Thanks for sharing with us mark would love to see it in the flesh when done

[pugeyed 0]

thanks dave

[pugeyed 0]

come on then folks put on your thinking caps.

bearing in a blind hole that i need to remove .

was thinking about welding a piece of metal in a u shape to it and using a slide hammer??
other options?

[lee1 1]

can you get a bearing puller in it?

[pugeyed 0]

no cus of that bit in the middle that buts right up to the back of the bearing.

[lee1 1]

@pugeyed wrote:

no cus of that bit in the middle that buts right up to the back of the bearing.

I know what ya saying mark but looking at the pic,it looks as though you could get a small bearing puller in there

if not looks like you will need to make some sort of hook,and get the slide hammer on it like you say

[XS1100 0]

Get yer Dremmal out and carfull grind or cut it in half tap it out?

[lee1 1]

or you could try this

http://www.oldbritts.com/b_removal.html

[firehawk 0]

how about putting the whole thing in the oven. Hopefully the housing will expand more than the bearing. Just make sure it doesn't contain any plastic or rubber first.

[firehawk 0]

Damn it. Lee beat me to it

[pugeyed 0]

well tried the dremel cant quite get to the bottom of the inner shaft to cut through it.

stuck it in the oven for 45 mins , nope aint movin an inch.

looks like it will be the slide hammer technique.

[lee1 1]

@pugeyed wrote:

well tried the dremel cant quite get to the bottom of the inner shaft to cut through it.

stuck it in the oven for 45 mins , nope aint movin an inch.

looks like it will be the slide hammer technique.

might need to leave it a bit longer mark,then try to pull it out,the bearing that is

[pugeyed 0]

got it out in the end , dug out a few of my very old pullers, nothing new would touch it, came out no problem.

new one on the way.

swingarm caps turned up today from the US of A

[fr499y 0]

got a few of them old buggers down the shed!

[pugeyed 0]

ive broke sooo much new kit , hate to sound old but stuff is not made like it used to be.

[Stue11 0]

@pugeyed wrote:

ive broke sooo much new kit , hate to sound old but stuff is not made like it used to be.

Your right there Mark

[dick65 0]

@Stue11 wrote:

@pugeyed wrote:

ive broke sooo much new kit , hate to sound old but stuff is not made like it used to be.

Your right there Mark

i still use some of my grandads tools

[pugeyed 0]

havnt got internet at the mo so wont be on here for a while, will update when i get internet back.

[spence 0]

Just found this....what a fantastic read, excellent pics too........hurry up and update..

[pugeyed 0]

hi spence thanks for the comment.

progress has been slow as of late, various things happening in life which changes how important things are , so project has gone to the back burner for the time being.

what i can update is genuine NOS main gear box bearing has turned up from USA today.

here is a crappy phone pic, (see the groove all the way around it)




this means i can now start to put the bottom end back together.

ill be using this stuff for assembly , have used it before it dissolves in oil which is good
http://www.ebay.co.uk/itm/300637091686?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1497.l2649#ht_623wt_1270

con rod shells and crank shells turned up from USA too

again sorry for slow progress , it will get there in the end i promise.......

keep yours eyes on the project , its on its way soon

[dick65 0]

nice one mark, hope alls well m8

[madsod 0]

one day at a time MARK hope all goes well in the end

[Stue11 0]

@madsod wrote:

one day at a time MARK hope all goes well in the end

[pugeyed 0]

so things have been quiet from this lately so thoght i would revive it !

stripped and rebuilt the final drive, was a bit daunting at first but is ever so simple really.

only thing i have changed is the seals as all bearings were in brilliant condition and if you replace any bearing you have to set up the gear lash .

here is a pic.


currently doing the middle drive , which again is nice and easy, just changing all the seals as would hate for them to leak as i go down the road for the first time.

[madsod 0]

nice to see its back on track , keep it up Mark

[lee1 1]

nice one mark you will get there

[Stue11 0]

Keep up the good work Mark

[dick65 0]

nice one mark

[pugeyed 0]

so i needed to repair the top crankcase as somehow it has been damaged.

so i bought some of this today,

have never used it before but its great stuff.
and it goes rock hard within 1 hour.
tried to snap it off but its well stuck on there and you can paint over it too.




hopefully wont notice it when its painted and back together.

[Oldfart 0]

Lookin' good. Look forward to seeing the finished article

[dick65 0]

tidy job mark

[lee1 1]

[Stue11 0]

[pugeyed 0]

had some top yoke blanks made up with stainless steel buttons .



think they'll look cool when fitted !

[fr499y 0]

Awesome its coming along nicely!

[dick65 0]

great tips there,ive just got an xj 900f shaft drive so im watching this with interest

[madsod 0]

nice like the dash also