As some of know I recently inherited my Dad's vintage Yamaha and have been working to, not only restore the bike, but to restore my soul after losing my Dad on Christmas. Anyway... I figured I'd give a bit of an update, so here is what I've been up to for the last couple of months (at least in between all of the honey do tasks). First I gave it a bath. Check out the video to see just how bad this bike looked up close before I went to work on it.Check out the video to see just how bad this bike looked up close before I went to work on it.

It looked decent from a few feet away after all of the grime was washed off... but it still had quite a bit of rust and aluminum corrosion to deal with.


The brakes were a basket case, which wasn't really a surprise given they still had the original brake fluid in the reservoirs. I completely disassembles the front a rear brake systems, thoroughly cleaned all parts, repainted and cured (baked at 200° for one hour) the master cylinders and calipers and then reassembled using OEM rebuild kits and new brake pads. The brake hoses will be flushed thoroughly before being hooked back up to the system.





I used a product called Amazon.com: Workshop Hero WH570295 Metal Rescue Rust Remover - 5 Gallon Pail: Automotive@@AMEPARAM@@http://ecx.images-amazon.com/images/I/41K6F%2B8axEL.@@AMEPARAM@@41K6F%2B8axEL to remove the rust on any parts that I couldn't sand and repaint (like chrome parts, etc.) This stuff works great and the best thing about it was that I could soak the parts in it without it hurting any paint, plastic, rubber or anything else that wasn't rust. Just check out the before and after in this next photo... all I did after a 12 hour soak was rinse with fresh water and wipe with a terrycloth towel.


Then Came the engine and frame. They both had a significant amount of corrosion to contend with and it took a LOT of hours of sanding, priming painting and polishing to make it all look like new. I even took the gauges apart so I could soak the bezels in the metal rescue to ensure no corrosion is left on this bike.


Next came the wheels. The cast aluminum alloy was dull and slightly pitted so I took the old tires off (replacing the old original tires with a new set of Michelin Commander II tires was something I intended to do anyway) and polished the bare metal using 400 to 1000 grit wet dry sandpaper and metal polish on a bench grinder with a series polishing wheels. After that the paint, which at first seemed fine, looked bad. So I spent six hours taping off the shiny bits and painting the rims with black caliper paint (durability and chemical resistance). These of course had to baked at 200° for an hour to cure as well.



I tried to find some original exhaust pipes that I could have re-plated with chrome or better yet some that wouldn't need it, but the only ones I could find were in worse shape than the ones I had. I got lucky and found a set of new old stock Jardine slip on exhaust that utilize the existing headers. The plan is to use these while I keep my eyes open for a good set of OEM pipes.


So... this is what she looks like right now. I've begun working on the tank and side covers (next photos).


The tank came out great after I took a clay bar and some Carnauba wax to it. In all of fifteen minutes that tank with the 34 year old original paint looks like new. I also took some Meguiar's Ultimate Compound after the side covers, you can see the before (bottom cover) and after (top cover) in the picture. Eventually I'll get the windjammer and saddle bags polished up as well and I'll update this thread.



The only major thing I have left to do is to disassemble, clean/polish and rebuild the bank of Mikuni MK2 carburetors I purchased that were on a 1979 XS750. These carbs are easier to work on, parts are readily available and they're easier to sync than the Hitachi carbs that came as OEM. This is crucial with the higher flow exhaust and the pod air cleaners that I'm going to be using. I can rejet the Mikuni carbs so I don't run lean and burn up the engine with that much more air being fed to the engine. I'll update this thread as I get things done and when she's complete I'll post another video showing her up close so y'all can see how great she looks.

Undoubtably a labor of love. I admire your patience and attention to detail.
I'm more into old tractors and other pieces of farm machinery, but I can relate
to the desire to put your Dad's bike back "the way it was."

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Georgia On My Mind

You will have a beautiful bike with a very special meaning when you
are through. Your Dad would be pleased. Enjoy riding it!

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Goose
I'm still standing.

That's a very nice bike. It reminds me of the early Gold Wings from the late 70's and early 80's when a nice touring bike didn't have to be so massive and have every accessory known to man on it. Those are the perfect size bike to just get on and go and cruise.

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Vaya con Dios

Beautiful motorcycle.

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<><

You're doing great work. Smart move on the carbs. Even without the exhaust change, you would need to rejet, just because of all the reformulations of gasoline since the 80s, plus it was probably stupid lean from the factory. You didn't mention the inside of the tank. It would be a good idea to get a clean and seal kit for it.

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Wayne
Torn & Frayed

I have a boatload of Mikuni jets left over from my MC days, send me a PM if you are interested and you can have them.

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Jim
Many K and N Frames

Sorry for you recent loss but it's a nice thing that you are doing there.

My first motorcycle was a '79 Yamaha 750 Special so your photos brought back some memories!

Nice job so far...enjoy and be safe!

Matt -

I remember looking at those bikes when they were in the show room in the 1980's. I ended up with a Virago. You are doing a fine job and I look forward to the final product.

Keep the shiny side up!

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Dave

Sir, you are an ARTIST! My gosh, what a labor of love.
I hope you have some group meetings or rides around your area in which to show her off when you're done making it immaculate.

parallel and glenncal, remember that there are several different kinds of Mikuni jets for different types of carbs. Wow, anyone who has Mikuni jets that they don't want, I'll take them. Especially big ones.

Attached Images

wayne2.jpg (104.4 KB, 65 views)

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Wayne
Torn & Frayed

NICE! I had a 650 Special in the early eighties. Wore it out once, rebuilt the engine, and wore it out again. Mine also was a full dresser. Lots of good times!

My hat's off to you. What a beautiful and noble restoration. I am the happy steward of a 1982 Yamaha Virago 920, so I appreciate these wonderful early Yamaha's. I look forward to seeing your progress, and condolences for your loss. PTL.

Very nice job!

Parallel, your thread is motivating me to get moving on my old bike. I've got an old crotch rocket('93 CBR900RR)that has been sitting for way too long. Mostly because of health reasons. And for the same reasons, I won't be able to do much of the work myself, but I have decided to take it to a shop next week & figure out what it's going to cost to make it right. If it's not too prohibitive, I'll go ahead with it. Then I'll have to decide if I'm going to keep it or part with it. I've said many times that I wouldn't sell it to just anyone who might turn it into a "stuntah" bike. Why this would bother me if I no longer own it I can't explain...I guess I would just hate to see it used that way.

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Lounge Lizard Extraordinaire

I had a bike just like that when I was a teenager. I traded a dirtbike for it. It was in good condition, except it had a dent in the top of a gas tank. Judging from the location and size of the dent, I expect that whoever put it there was in a great deal of pain after it happened.

My mother thought it was too big and scary for me, so I sold it and bought a 1000cc Sportster. I guess it didn't look as big to her without the windshield and saddlebags, because she never said much about it.

That'll be a very special memento of your father. I'll bet he'd be proud of the work you've put into it.

That bike is a rolling tribute to your father. It's good to have something like that of his. It will help you keep that memory alive in your heart and in your mind for years to come. Wherever you go on that bike, he will riding along with you...

L8R,
Matt

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SD40-VE owner and proud of it!

That reminds me of my best and last bike, a 82 Yamaha 750 Seca.

I recently put a set of Michelin Commander II tires on my Virago, and even though I have always used premium rubber, these are the best I've had in over 20 years.

I guess I shouldn't be surprised that these 35 year old Mikuni MK2 carburetors are fighting me every step of the way on getting them disassembled. They are old and obviously have never been serviced (and they STILL cost me $200). I've soaked them for DAYS in Marvel Mystery Oil and sprayed the Hell out of them with Blaster 16-PB Penetrating Catalyst and a host of other penetrating oil and the fasteners are STILL fighting me every step of the way.



I bought a good set of JIS (Japanese Industrial Standard) screw drivers before I even contemplated tackling this job and I have been as careful as I can possibly be and I STILL buggered up a few of the screws. The worst part is that I'm still not completely finished with dis-assembly so there could be even more issues (hopefully NOT with jets because THAT would be really bad). I've even spent well over $100 on even more tools designed to deal with stuck fasteners. At least thus far those tools have at least worked albeit very slowly.

It's not all bad news and bellyaching though as I did manage to avoid one of the common pitfalls. I've read the lots of dire warnings on the Yamaha Triples forum about snapping the float post off while trying to remove the float pins. I certainly did NOT want to do that so I went searching for solutions and I came across a stunningly simple one. An automatic (spring loaded) center punch. I got mine from Sears for about $10.00... worth every penny. At least SOMETHING has gone right with this part of the project.

I made a YouTube video to demonstrate.

When working on motorcycles, an impact driver is your friend.

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Wayne
Torn & Frayed

Are we talking the type that you hit with a hammer and it turns 20° or so at a time or something different? I bought one of the ones I just described and it worked somewhat... but some of the fasteners are so small and frail that it wouldn't work on those.

tap-tap-tap on those screw heads...

And heat. Old fuel has probably turned into red threadlocker by now.

Excellent project! Look into a MSF basic course if you haven't already!

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ΜΟΛΩΝ ΛΑΒΕ

This is a 44mm Mikuni on the Sportster. Worked great till about 125 MPH then it would freeze the slide open and I mean ICE. What I really needed was a couple of 38's. Settled for an S&S. Not nice when you can't shut your machine down.

DW

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"NUTS"

I just discovered that some of these screws have been peened. So... looks like I'll be filing off the peened threads... that should help a bunch. Also, I bought a small butane torch (the kind you can adjust the flame and even solder with) that should help a bunch as well.

Also, I took a course at the Harley Davidson Riding Academy (formerly "Rider's Edge") a couple of months ago. It was a great refresher course for me as I had not been on a motorcycle in 30 years and even then they were dirt bikes. It was amazing how fast it came back to me though. Within ten minutes I could concentrate on the road centric info and not worry about the basics.

If the brake hoses are 34 years old, please consider replacing them, especially if you are going to ride any distance. There are sources for stainless braided units made to your specs.

Also, if there are problems when you try to start it, check the electrical connections. Older bikes are famous for corroded connections.


Tom In Cincinnati

70 Benelli 250 (gone and good riddence)
74 Honda CL450 (gone)
75 Honda CB750K2 (gone)
94 BMW K1100LT ( now my BIL's bike)
06 BMW R1200RT- "the Ruptured Duck" my retirement bike

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Long Barrel
Retired Artilleryman

Your father would be proud of you and his bike.
Nice job so far! Lets see a big smoky patch when youre done sign your driveway .
i learned to launch my camaro in my driveway, neighbours loved me especially once it had mufflers

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the rules? there are no rules

Thanks LB. I did order a stainless braided brake line set from Paragon Performance the day after I posted this OP. I was surprised to discover that, at least the set I got, didn't come with new banjo bolts as the others I'd seen did. So, I'm awaiting a shipment of new banjo bolts to come in from mikesxs.com so I can get them installed.

Also, I ordered and installed a new OEM type fuse block (again from mikesxs.com) as well as checking all of the connections. I've yet to start her up (or even power her up) so I might find something unexpected when I do... but it'd have to be something deep in the system for me to have missed it.

I have a love/hate relationship with mechanically minded folks.
I have two scew drivers---one to tighten and one to loosen.
I can't think like a machine.
Blessings

PS----I am loving the posts

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TEXAS, by GOD

Williamlayton, you've seen one of my mechanical challenges, a man's got to know his limitations, right?

Parallel, you have an inspiration to build a monument, I salute you.
jim

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Halfway and one more step

That's the one. I use a screwdriver set with magnetic tips and adapt them to the driver, so I have all kinds of tips. I can't imagine taking clutch covers off without one. Working on bikes is a great experience for learning efficient persuasion. Keep at those carbs, use carb cleaner, and gloves. If you use any aerosol, use safety glasses, and keep your mouth shut. I also hold my breath.

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Wayne
Torn & Frayed

^ ^
What wbraswell said, and the bernzomatic torch.

Huskys, CZs, Bultacos,XLCHs,Triumphs (Hinkley and real ones)BSAs and old Norton 500s, all the Japanese, (including Tohatsu)....I've had a bunch of 'em.

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Halfway and one more step

Great post; thanks for sharing!

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NULLI SECUNDUS

I am totally intrigued by what you are doing. The justification is the spirit that you are doing it in. If I had my dads last bike I'd be doing the same thing. I'm not a Jap bike guy but in this case I'm actually anxious to see the results. Good luck with those carbs.
DW

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"NUTS"

Good move on the JIS screwdrivers. Until about 15 years ago, I hadn't even heard of them, and always tried to make do with Pozidriv bits. Even so, the fasteners are made of compressed oatmeal and sometimes the only answer is to grind the heads off and replace them.

Speaking of old Yamahas, I saw a young guy today in the gas station filling up a gorgeous red SR500. He confirmed my guess that it was a '79. It had been his dad's bike, and now he was riding it with pride. He had "redone" it; I didn't get a chance to ask him what it meant, but it looked all stock except for the braided line to switch the oil feed from the intake to the exhaust cam.

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Not in jail.

Thanks y'all. I had a breakthrough when I discovered that the butterfly valve screws had been peened. I got a small file and filled the backs of them off and they came out fairly easily after that. I'm guessing all of the penetrating oil I've been spraying all over them made the rest come out fairly easily as well. They're all disassembled and two of three have been dipped for 30 minutes each in Berrymans. I'm considering taking them to a professional to soda blast them more out of expediency that anything else. I'd like for them to have that nice new aluminum satin finish before I assemble them.

I'm just awaiting a quote and a turnaround estimate to have these Mikuni MK2 Carb bodies and float bowls soda blasted. It's my own fault I couldn't get that today, I waited too long to call IBS and get them the info they needed. This is too large a job for my homemade soda blaster and I really don't want to have to take these down again so I'm just going to have to be patient and do it right.



While I'm waiting I went ahead and installed my new braided stainless steel brake lines complete with all new banjo bolts and copper washers... so when I NEED to stop, I can. Of course that meant tearing the whole front end apart again to get to the joint that splits the one line into two. I'm just going to have to deal with the fact that this IS going to take me longer than I would have liked.

Well... no place around here that dose soda blasting would take the job saying the parts are too small. So, I went and bought one of those Harbor Freight 15lb soda blasters and a 50lb bag of soda blasting media. The damned thing won't pick up the media so I've given up on the soda blasting... I'm just going to have to do this the hard way. A little metal polish and a LOT of elbow grease. I'm just going to polish the caps and bowls and leave the bodies alone. They aren't too bad anyway and I can just clean up the mating surfaces the old fashioned way. Here's the first set polished up (I could go further but I just want them clean not like chrome).

Parallel,
Carb float bowl screws are made of something that locks them in place and allows the heads to deform if you even think of removing them. I have part numbers for oem wiring connectors in my tool box at the shop if you need them.

Yep... I bought a set of stainless socket cap screws for these carbs from a guy on Yamaha triples forum who bought a bunch to justify shipping and sells them to others for cost. I rounded his asking price up to $11.00 for the set... worth every penny.

I finished the polishing of the caps and bowls today all while not feeling well and combined with the drama of my wife's side of the family dealing with rough times. The family had multiple destroyed homes due to the hurricanes that hit Mississippi last night. Then... this morning her young cousin, our live in babysitter for the last four summers, crashed the car we gave her. She's in the hospital and is expected to be alright but she has internal bleeding and bleeding on the brain. Suddenly this motorcycle I've been obsessing over was no longer the most important thing on my mind. For those so inclined... prayers are definitely appreciated.

Prayers sent

Prayers up, glad to hear she is still with you folks.

The MRIs she had this morning show that the bleeding both internally and on the brain has stopped. As she had no other serious injuries they've discharged her.

Thanks to all for the prayers and well wishes.

Prayers sent for a rapid recovery.

It's FINALLY time to reassemble these Mikuni MK2 Carbs and get them ganged together and installed so I can see if this bike is even going to run. With luck I'll be posting a video of the first start up tomorrow night.

I just prayed. Believe.

Prayers going. We're with her.

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Halfway and one more step

parallel, I admire your organized layout of your carbs. Looks like everything's there. Good luck.

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Wayne
Torn & Frayed