Boorrrringggg Build/Rebuild/Refres&restore

[bikerphil]

I would recommend using a gasket, this kit has the cam end plugs you will also need...

http://www.ebay.com/itm/YAMAHA-1978-...NS4vs~&vxp=mtr

[puskrat]

You shouldn't mess up any bolts unless someone went crazy on them

I'm the guy with the locked up oil filter bolt.

[puskrat]

I would recommend using a gasket, this kit has the cam end plugs you will also need...

http://www.ebay.com/itm/YAMAHA-1978-...NS4vs~&vxp=mtr

Aww, Phil. I was just about to buy a roll of gasket and start razoring.

Seriously, thanks.

[bikerphil]

Yep, I find that if you are using RTV sealer instead of a gasket, you need to be 100% perfect installing the cover or you risk having a leak. There is not much room with the engine in the frame to finagle the cover in place. Use RTV on the half moon cam plugs though.

[motoman]

The half-moon cam plugs I highly recommend using Hi-Temp Grey silicone sealer, not just any ole' RTV.

[3Phase]

I would recommend using a gasket, this kit has the cam end plugs you will also need...

The gasket looks a little ragged but at least comes with four cam plugs for your twenty bucks so there're a couple of spares.

I'm the guy with the locked up oil filter bolt.

Right. If they are that tight and they do get mangled but you get them out without ripping out the aluminum threads, get some new bolts. Here's a good looking set from a Midnight Special and it has the throttle cable bracket too for about $9 plus $6 for Expedited shipping:-
http://www.ebay.com/itm/80-YAMAHA-XS.../380884485516?

If the bolts are overtightened, the aluminum will start to lift up around the holes where the bolt threads started to pull out of the head. That makes little raised spots that'll cut into the gasket when it's tightened or just keep the cover from sitting flush on the head.

Before you put the valve cover back on, use a hammer with some round stock to carefully knock the aluminum back down around the bolt holes, then use a tap (best) or one of the bolts to clean up the threads.

Aww, Phil. I was just about to buy a roll of gasket and start razoring.

Seriously, thanks.

Heh, razors are dangerous, man, and the valve cover gasket is skinny and it's easy to tear it up. Use a good pair of sharp scissors like cuticle scissors and stay away from the ones in the wife's sewing kit.

For sealing the cam plugs, use Yamabond 4 or ThreeBond 1194.

[puskrat]

The gasket looks a little ragged but at least comes with four cam plugs for your twenty bucks so there're a couple of spares.



Right. If they are that tight and they do get mangled but you get them out without ripping out the aluminum threads, get some new bolts. Here's a good looking set from a Midnight Special and it has the throttle cable bracket too for about $9 plus $6 for Expedited shipping:-
http://www.ebay.com/itm/80-YAMAHA-XS.../380884485516?

If the bolts are overtightened, the aluminum will start to lift up around the holes where the bolt threads started to pull out of the head. That makes little raised spots that'll cut into the gasket when it's tightened or just keep the cover from sitting flush on the head.

Before you put the valve cover back on, use a hammer with some round stock to carefully knock the aluminum back down around the bolt holes, then use a tap (best) or one of the bolts to clean up the threads.



Heh, razors are dangerous, man, and the valve cover gasket is skinny and it's easy to tear it up. Use a good pair of sharp scissors like cuticle scissors and stay away from the ones in the wife's sewing kit.

For sealing the cam plugs, use Yamabond 4 or ThreeBond 1194.

The sewing kit gave up its snips To my fly tying bag years ago.

[puskrat]

While I'm waiting for my gasket et al, I need to score the valve adjusting tool. What should I choose?

[motoman]

I would recommend the tool from Yamaha. The MotionPro tool has to be ground in several places in order to work as smooth as the Yamaha tool.

[bikerphil]

The Motion Pro tool may need some grinding....

[dbbrian]

Uh-oh

Thats the one I bought to use next Saturday

[bikerphil]

Didn't take more than 10 minutes to modify, hopefully yours won't need it. The holes may need some enlarging also.

[puskrat]

How in the world do you know when it's right?

[3Phase]

It may take some work to fit a Motion Pro tool but some of them drop right in and you don't have to goof with them. You'll know it's right when the tool doesn't touch the cam when you try to bolt it to the head.

The Yamaha tool just works but it's also just seriously expensive.

The crankshaft has to be rotated clockwise and counterclockwise to use the tool so the bike has to be on the center stand or whatever you need to do to get it upright and level, then set the cam chain tensioner before tackling the valves.
If the cam chain has too much slack then the engine can jump time when you turn the crankshaft backward/counterclockwise. Assuming you don't lunch a valve, it still defeats the whole entire purpose of using the tool because you have to pull the cams to reset the timing.

[puskrat]

Seriously? I have to do the cam chain tensioner before the valves?

My frustation level.