My '79 re-do

[DiverRay]

I have my 1979 standard that locked up the transmission about 7 years ago. I am in need of "thinning the heard" because of room issues, so it's time to get it running once again.
Rather than splitting cases on an engine with 115K, I had an engine out of a 1980 Special with only about 35K on it. It had 2nd gear problems, but ran well when it was pulled out of Special Ed's bike in place of the hopped up '79 engine.
I started with the '80 engine, and put it on my engine stand to address the gear issues. I pulled the side covers and pan, and replaced or repaired what was needed in the transmission. As I put the engine together, I put in the '79 advance parts, cleaned the starter, and put in a good alternator as the one from the 80 was now on Ed's '79 engine.
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I then cleaned and painted the engine so it would look good, and stay that way.
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Next in line was the frame from the '79. I took everything apart, sanded the frame, swing arm, and other bits in prep for painting. I used a good satin black paint, and finished with a 2K clear rattle can paint. This is a 2 part paint in a can from eastwood. Once you mix the 2 parts, you have 24 hours to use the paint.
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I did repair 2 faults on the frame with the TIG welder before the paint went on.
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Next was the new shoes, mounted and balanced by a local shop. I didn't do much with the rims, as they had all new bearings and grease just a few thousand miles before the "sleep". I DID check and repack bearings, but as I used the synthetic grease, they had NOT hardened up.
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I started with the engine done, and used a lift to get it on the floor. I put it on it's right side, and lowered the frame onto the engine. As I was doing this alone, this was the best way of getting them back together without scrating the paint. I ran the rear mount bolt through the engine, and istalled the front mount snug, but not tight.
I then used a lift and straps to hoist the engine and frame so I could install the swing arm, front forks, and then the wheels.
I then put on the side stand so I could move and park the bike as I worked on it. Remember, I have a 1 car garage, with two bikes, tools, and other things that must all fit the small space.
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end of first part!

[MarkD]

Looking real good, Ray.

[DiverRay]

Next part:
Next up was the carbs. They had been sitting for a long time, and needed some help! I started with my acetone/ATF de-rust on all the screws a day before I tried to take things apart. Once apart, I put everything into the ultrasonic cleaner with Pinesol. After about 20 minutes even the worst of the junk was soft and ready to come off. I then rinsed everything VERY WELL in HOT water, and used air to blow out all the ports.
I lubed and assembled all the bodies, and painted the covers black to match the engine. I installed the carbs with the 7 year old holders from my '79, and NOT the 35 year old ones fron the engine.
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These are the carbs mounted and after running for a bit.
I then got the brakes ready for the road once again. As they had been rebuilt with DOT5 fluid, there was no water, and no problems with brakes sticking, even after the 6 year sleep! I installed new pads for the fronts, as they were less than 50%, and the rear was still good, at about 70%.
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I could now push and stop the bike easily with the brakes, so it was time to get the carbs back on. I cleaned up the air box, put some "secret sauce" on the rubber to soften it, and got the top of the airbox into the frame. I then installed the carbs, with a new throttle cable, and put the airbox on and back together.
Now all I needed was an exhaust system, and it would be ready to start!
I had the Kerker headers that was on the '79 when it was parked, and that is what I was goint to use. I cleaned all the rust off with a sand blaster and wire wheels, sanded, and then applied the high temp exhaust paint in flat black.
The "muffler" on the system had a new insert at one time, but it was in bits and parts on the inside, and didn't work well. Kerker is no longer around, and the inserts from EBay just didn't look right to me. I was able to get 18" of 1.5" pipe from a muffler shop, and build my own insert. I put it all together, and when I fired the engine up it wasn't TOO loud. I will be pulling the insert and putting some fiberglass packing on the inside to quiet it down a little. I'm trying to put this bike together as a touring bike, and I don't want a "loud drone" as it makes for shorter rides.
The bike is together, other than all the body parts, so I was ready to start the engine and adjust the carbs. I knew I had gas in two of the carb bowls, as I had done some leak testing BEFORE installing them. I turned the key on, pulled the "choke" and hit the starter button, not expection much as I had not connected my remote fuel tank yet. The bike fired and tried to run on the 2 cylinders!
I then hooked up the remote tank, fired up the engine, and turned down the idle just a bit once it had run for about two minutes to warm up. With the fan in front, I then set about adjust the mixtures and sync. Bench sync was close, less than 1 turn on any one screw. Idle mixture was off a bit, but not bad. I had the bike done in about 20 minutes. It sounded NICE, but LOUD when it hit about 4.5K RPMs.
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I did need to fix some of the wires, so I cut and installed new connectors in place of the cracked ones.
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I am now sanding down the Pacifico Fairing, and working on the rest of the parts getting the bike ready for paint. I am going to paint it Black, with a silver stripe down the center. Picture will come later as I get more done.

[3Phase]

Oh, yeah! Lookin' good!

.

[madmax-im]

great job Ray...keep it coming..

[Gmac]

Very nice

I have a question about your ultrasonic cleaner, how big is the immersion tank?
Do you happen to have a picture of it?

The reason I ask is because it's one of those tool investments I'm going to have to make and I don't want to go to small, preferably large enough for the rack of four as taking the rack apart doesn't sound appealing and I'd prefer to spend the money to make the job easier.

[Gmac]

Ps...

That is starting to look pretty good!

[DiverRay]

The cleaner will only hold 2 carb bodies at a time. The large cleaners are NOT affordable for me, at about $300 for a cheap one. Mine is the harbor freight 1.2L model, IIRC. I bought it about 6 years ago, so I don't know what is available now.

[jwhughes3]

I have a question about your ultrasonic cleaner, how big is the immersion tank?
Do you happen to have a picture of it?

The reason I ask is because it's one of those tool investments I'm going to have to make and I don't want to go to small, preferably large enough for the rack of four as taking the rack apart doesn't sound appealing and I'd prefer to spend the money to make the job easier.

George,

I bought one of these a couple years ago - it fits a rack of four without the plastic basket diagonally.. It does an excellent job with the PineSol solution.

http://www.ebay.com/itm/6L-1-5G-ULTR...item1c1e9294a2

I think there are other 6 liter tanks out there too slightly less $. Can't speak to XS carbs fitting though.

BTW the bike is looking great Ray!

John

[Gmac]

Thanks JW

The EBay link made me start wish casting again and for 'just a little more' I found this one that will hold a full rack and is industrial.

http://www.ebay.com/itm/Pro-Stainles...item2ed6d74240

[jwhughes3]

Wow 15 liters!

Very nice.

John

[3Phase]

Now I want one too!

[yamtom]

about the vendor

Now I want one too!

Ive had good luck, just with the pinesol, the genuine article, not generic pinesol, or for the ones with big bux,,, yammie cleaner,,and soaking , triple clean, carb cleaner spray thru , well you know the rest.

You better check this vendors other items for sale, they are not exactly professionally dedicated to the ultrasonic cleaner , are they !! haha

Everything else I saw, seemed to be very emblematic of the chinese crap stuff, hope the cleaner holds up well, but these guys are common chinky sellers by the look of things.

Ive bought lots of chink stuff on ebay, its all low end, and anything complex from chine, dies young from my experience. Buyer beware.

[jwhughes3]

Would it not be ironic to find out the original Yamaha carb formula is actually PineSol without the piney scent?

It kinda turns whitish like PineSol when mixed with water.

John

[DiverRay]

Well, a little more work this weekend. Prime and check fairing and plastic parts in prep for next weekend, the color....
First, mostly done with the sanding on the fairing.
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Next, a second look.
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And a shot of the inside of the 35 year old fairing, with my other bike in the background. Didn't see that when I took it, but I like it....
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Some of the other parts hanging out in the one car work space. The lowers had NEVER been installed on ANY bike!
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This is the tank that will be going on the bike in the background. It, like the rest of the bike, will be black with silver flakes.
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The fairing AFTER a coat of primer/sealer. This primer is made for both plastics AND metal, though I will use a self etching primer on the tank...
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Some of the 30 years of wear I need to address. I HAVE used a two part plastic epoxy to glue everything back together, now I just need to fill in the stuff that shows.
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More in a few days....