Steel frame Yz450f build

[ss-racing]

long story short, I bought a rolling chassis in 2018 and  wanted to use some of the parts for my 2-strokes,  and never sold the rest  ? so it was cluttering the place up and decided it would be easier to sell a whole bike versus a mess of parts. 

above is the mockup of the 2003 chassis with the 2005 suspension ... below is the engine 

 

Edited September 27, 2019 by ss-racing

[ss-racing]

 

here’s a more complete mockup of the chassis. Bought a new plastic kit and used air box . 
...and yah, about that engine . Replace your timing chain regularly folks! Three titanium intake valves ruined.  ... or are they ? ?

Edited September 28, 2019 by ss-racing

[adam728]

Three titanium intake valves ruined.  ... or are they ? [emoji12]

I'll take "They are eff'd" for $400, Alex.
[emoji1787]

[ss-racing]

Lest y’all think I’m a wizard that can do this in my sleep ....this was one of the first things I purchased. 
Repeat after me, you can’t do factory work without a factory manual. 

it’s small money that will pay for itself over and over, especially if you put something together wrong and ruin a mess of parts.

 

Edited September 28, 2019 by ss-racing

[ss-racing]

 

slow progress when you’re assembling , but you didn’t do the disassembly  ?

Always remember , it only goes together 1 way correctly. 

 

 

Edited September 27, 2019 by ss-racing

[ss-racing]

 

while working on the engine I had the local powder coat house refinish the frame. 
 

i pays to just bite the bullet, break out the tap and die set, and chase every thread on the frame. They plug them but it still flows in there. 

Edited September 27, 2019 by ss-racing

[ss-racing]

Intermission: had to go to Budds Creek

[ss-racing]

fast forward a couple weeks, replaced piston, rings, intake valve guides, intake valves everything tested good,  took some time to get the required shims and get those installed. Once the engine was buttoned up, I carefully placed it in the frame.

[Motox367]

Does it run? ??

[ss-racing]

Another intermission: had to go do some Moto with my buds

hell ya I dusted em ! ?

[ss-racing]

So here’s what it looks like now

 

[ss-racing]

One of the things in the service manual is a lubrication diagram , if you’ve ever spent significant time in one of these engines , you know the oil system is pretty extravagant.
I wanted to be assured it was working properly before I started it, so after pouring a liter of oil in it, I spun the crank with a drill for about a minute, but no oil pressure at the top end . 
Needless to say I was a little concerned, but thought that the crank speed was perhaps not high enough. 
Once I got the hot start plunger installed in the carb, I started it up and waited for 15 secs at idle .... still no oil pressure so I shut it down immediately and launched an investigation that would’ve had raised the eyebrows of Nancy Pelosi?

 

[ss-racing]

 

what I didn’t know when I bought this engine was it had a lubrication mod done to it  to make the 2005 engine like a 2007. Just like what’s pictured here , it uses a 07 oil pump, and that little nozzle fits into the custom machined passageway located at 1:30 from the oil filter housing.  The purpose is to spray a small jet of oil on the underside of the piston, evidently for cooling and wrist pin lube.

Anyway, I drained the fluids that day and inspected the cover, when I saw that hole, I knew something was supposed to go in there... a plug at the very least.  Shorty thereafter, I came across this pic on the web and recalled seeing a part like that nozzle in the bag,  sadly, it was broken.  
 

for reference: Yamaha 5D3-15155-00-00 Nozzle

once installed , builds oil pressure perfectly ?

[SteveThe Snakes]

The only question is do you have more in the rebuild than you can sell the bike for. ?

[ss-racing]

I fired it up a couple days ago, seems to run fine.  As expected , more than a minute sitting still and the powerbomb starts glowing red. I’m currently missing the clutch cable holder that mounts on the engine, otherwise I would’ve taken it for a shakedown run already. 
 

to be continued 

Edited September 28, 2019 by ss-racing

[ss-racing]

24 minutes ago, SteveThe Snakes said:

The only question is do you have more in the rebuild than you can sell the bike for. ?

Probably a break even scenario at the moment (assuming my labor rate is $2/hour)  ?

[Motox367]

17 minutes ago, ss-racing said:

I fired it up a couple days ago, seems to run fine.  As expected , more than a minute sitting still and the powerbomb starts glowing red. I’m currently missing the clutch cable holder that mounts on the engine, otherwise I would’ve taken it for a shakedown run already. 
 

to be continued 

Lean why they usually do that

[SteveThe Snakes]

Just now, ss-racing said:

Probably a break even scenario at the moment (assuming my labor rate is $2/hour)  ?

Still looks good though. Probably worth just keeping. 

[ss-racing]

2 minutes ago, Motox367 said:

Lean why they usually do that

I don’t plan on running on the pilot much.  WFO man ! ??

seriously? You think the stock pilot is too lean ... bump it up 1 ?

[SteveThe Snakes]

I know what it’s like firsthand. I used to get my parents Cadillac’s when they bought a new one. They would buy a new one every few years when the warranty was about over. They sold them to me for a great price. The only problem was they had so many do-dads on them something would always go bad causing repair lights to go on. When I went to sell them I always fixed everything. The problem was it ended up costing me right about what I sold the cars for every time. ?