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Kiwialfa
20-10-15, 02:59 PM
Started disassembling the Yamaha DS5-E that's been lurking in the shed since the late 1970s and was greeted by a chemical garden.

http://i1300.photobucket.com/albums/ag97/KiwiAlfa/Yamaha%20YDS5%20Restoration/20151018_212252_zpskme9t0ab.jpg

http://i1300.photobucket.com/albums/ag97/KiwiAlfa/Yamaha%20YDS5%20Restoration/20151018_212143_zpsfboqz3b5.jpg

http://i1300.photobucket.com/albums/ag97/KiwiAlfa/Yamaha%20YDS5%20Restoration/20151018_214514_zpsmi5kboas.jpg


Some how the oil in it has been replaced by a watery yellow-green liquid. Further investigation to assess the viability of resurrection.

83KAT
20-10-15, 03:25 PM
G'day Kiwialfa, It looks like it has had water get into it.

Toadboy
20-10-15, 03:30 PM
Mix that lot up and you'll probably win the Nobel prize for coming up with a cure for 'everything'......:)

It'll be recoverable for sure, might just be a bit more work than first thought.

Good luck.

Kiwialfa
20-10-15, 03:34 PM
Your not wrong 83KAT, appears the crank has seized too. RH barrel came off no issue - has new pistons and rebored/honed barrel. LH side looks to have water ingress as well and the piston is playing hard to move. Soaked it and now it may resort to a little heat and a big rubber mallet!

Kiwialfa
20-10-15, 03:55 PM
Mix that lot up and you'll probably win the Nobel prize for coming up with a cure for 'everything'......:)

It'll be recoverable for sure, might just be a bit more work than first thought.

Good luck.

Or possibly "a cause of cancer":-D Splitting cases will reveal all.

ThomasJ
20-10-15, 05:55 PM
Yuk!!!!

What is the bike in your new avatar?

Kiwialfa
20-10-15, 10:24 PM
Yuk!!!!

What is the bike in your new avatar?

Vincent powered Guzzi!

Kiwialfa
03-11-15, 10:38 AM
After much pounding with soft faced mallets, wiggling and gentle prying.
http://i1300.photobucket.com/albums/ag97/KiwiAlfa/Yamaha%20YDS5%20Restoration/20151102_212954_zpslrj3n9h0.jpghttp://i1300.photobucket.com/albums/ag97/KiwiAlfa/Yamaha%20YDS5%20Restoration/20151102_212941_zpsqt8bypyv.jpg

Full crank rebuild required, new bearings in the gearbox too. Gears look OK on first blush, but cleaning them up will tell the full story. I'll get the engine sorted and think about where I go with this. Either a resto, or possibly an old school classic cafe racer. The YDS5 was the basis for the TD2 "over the counter" road racer (https://en.wikipedia.org/wiki/Yamaha_TD2).

http://i1300.photobucket.com/albums/ag97/KiwiAlfa/Yamaha%20YDS5%20Restoration/20130915_134508_zpsbc7hzss9.jpg

83KAT
03-11-15, 11:16 AM
:-o..Good luck

ThomasJ
03-11-15, 12:54 PM
You have a lot more patience than me.

Kiwialfa
03-11-15, 01:37 PM
Thanks 83KAT, it's actually not as bad as it looks.

Idle hands, they say, are the devils playground ThomasJ. Although enjoying fcking around with dead bikes might qualify as a form of necrophillia... Until you get them running again and that's necromancy.

ThomasJ
03-11-15, 01:40 PM
Idle hands, they say, are the devils playground ThomasJ. Although enjoying fcking around with dead bikes might qualify as a form of necrophillia... Until you get them running again and that's necromancy.

Sick puppy........ LOL!!!!!!!!!

Kiwialfa
04-12-15, 09:39 AM
Progress

http://i1300.photobucket.com/albums/ag97/KiwiAlfa/Yamaha%20YDS5%20Restoration/20151202_2247131_zpsox4eqoyw.jpg
http://i1300.photobucket.com/albums/ag97/KiwiAlfa/Yamaha%20YDS5%20Restoration/20151203_1944031_zpsdwi9vahl.jpg

83KAT
04-12-15, 05:55 PM
Looking good, cheers Ian

peteGSX
05-12-15, 09:08 AM
Ooooh pretty!!! Nice work!!

What process did you use to get them like that?

ThomasJ
05-12-15, 12:13 PM
What a difference, looking good

Kiwialfa
06-12-15, 09:02 PM
Thanks Guys. Keeps me out of trouble and I'm quietly excited about getting a 49 year old two stroke back on the road. I owned a few strokers when I was a pup, including a GT250, an Kwaka S3-400, two RD400Es and assorted trail bikes.

I soda- blasted the cases - I have Supercheap cabinet but its a dusty process as the blasting soda crystals turn to fine powder and it goes everywhere, however its brilliant on alloy becauses it removes the crap with no erosion of the alloy. Hard deposits I attacked with soft brass brushes including a couple of rotary fitments on my air die-grinder. And some very careful work with rotary steel brushes on the die-grinder as they do scratch.

The blasting is followed by hot suds and water (dishwash liquid) and heated to dry. Then masked off, using the old oilseals with the holes taped up as plugs to keep the bearing surface clean, and rolled-up bog roll in other orifices (not mine). A coat of Duplicolor engine enamel primer then 3 coats of Duplicolor 'Aluminium' Engine Enamel with a 15 minute flash time in between coats. Let them dry for 8 hours and then I baked 'em in the oven at 130 centigrade for 30 minutes.

This is the same process I used on the Kat SXZ engine with really good results. The finish is hard and doesn't scratch too easily.

There is a bit of corrosion pitting on the internals of the engine cases, but none is located where it would matter. The primary drive gear, both crankshaft and clutch, had a small section where the gear teeth had rotted in to sharp points. Got a complete clutch in excellent nick for US$30 on eBay. Other bits and pieces on the way from the US and the UK. Carbs (it had none) are sourced and it will need a rebore. Got all the bearings on the crank freed, and the big ends might be OK. I got a cheap 12 tonne shop press last weekend and will press the crank apart and press new bearings into the cases next. I plan to do as much work of the work as I can, including rebuilding and truing the pressed crank, all painting (frame tank and panels), and hand beating a seat pan out of sheet steel -hopefully my skills will rise will match my ambition. But if you don't try you don't learn.

peteGSX
07-12-15, 07:16 AM
Great stuff mate, they came up a treat!

I'm keen to see how that seat pan turns out. I like working with steel and aluminium but just don't have the skills/tools to do it much justice aside from some pretty simple bends and curves.

Kiwialfa
07-12-15, 09:34 AM
Great stuff mate, they came up a treat!

I'm keen to see how that seat pan turns out. I like working with steel and aluminium but just don't have the skills/tools to do it much justice aside from some pretty simple bends and curves.

Don't know if I have the skills/tools either Pete. I haven't beaten a curved depression in sheet metal since high school. But I'll give it a crack, and you son't see the seat pan on the assembled bike, so its a good place to start/experiment.

Darryl

peteGSX
08-12-15, 07:27 AM
Yes true, always good to try on something you won't see! Looking forward to seeing it all the same...

Kiwialfa
22-12-15, 08:53 PM
Got the correct speedo for the YDS. Inspiration for the Kat clocks, perhaps? http://i1300.photobucket.com/albums/ag97/KiwiAlfa/Yamaha%20YDS5%20Restoration/20151222_215351_zpsaltuoxoe.jpg

Kiwialfa
26-12-15, 10:16 AM
http://i1300.photobucket.com/albums/ag97/KiwiAlfa/Yamaha%20YDS5%20Restoration/20151102_212954_zpslrj3n9h0.jpghttp://i1300.photobucket.com/albums/ag97/KiwiAlfa/Yamaha%20YDS5%20Restoration/20151225_235808_zpsac22wyxj.jpg

Dropped in the new bearings. Heated the cases and froze the bearings. A smear of moly assembly lube on the outer races and they just dropped in. The heat equalised and the bearings locked into position.

Kiwialfa
29-12-15, 10:01 AM
Frame ready for undercoat. After dip stripping the tanks and panel parts are in good nick under the paint. Everything is zinc phosphated.

http://i1300.photobucket.com/albums/ag97/KiwiAlfa/Yamaha%20YDS5%20Restoration/20151229_110446_zpsxfvthekq.jpghttp://i1300.photobucket.com/albums/ag97/KiwiAlfa/Yamaha%20YDS5%20Restoration/20151222_161447_zpsnjbw0ihr.jpg

Kiwialfa
23-02-16, 09:35 AM
http://i1300.photobucket.com/albums/ag97/KiwiAlfa/Yamaha%20YDS5%20Restoration/20160223_102625_zps1tpft4lm.jpg

Crank webs have turned up. Good old fleabay. The originals ones were a bit too corroded at the centre labyrinth seal area to be useful, and they all had to have the outer edges of the webs turned to allow the crank to be trued. I have new rods, pins and bearings ans will use the old crank bits to practice pressing the bugger back together. Frame, swing arm, stands, battery box, etc. all painted in satin black. Need to sort out the kick shaft, which at some stage has been turned down and re-splined for smaller diameter kick lever assembly. Being a LH kick, I suspect a Suzuki T250-305-350-500 would fit. Once sorted the engine reassembly can begin.

Toadboy
23-02-16, 11:36 AM
Sweet :)

Coming together nicely Darryl.

Kiwialfa
23-02-16, 04:11 PM
Sweet :)

Coming together nicely Darryl.

Albeit slowly. Still, it's nice to save a bike from the scrap heap.

Nick Kakasiouris
23-02-16, 11:16 PM
Well done my Kiwi friend and keep going as when finished it will be a credit to you for your effort.
Nick

peteGSX
24-02-16, 07:56 AM
Very nice indeed! Can't wait to see her come back together!

Kiwialfa
24-02-16, 08:46 AM
Very nice indeed! Can't wait to see her come back together!

Thanks Pete, I'm really enjoying watching your Kat build. That sense of achievement with every step forward is just great. Looking forward to your Kat's birthday and some on the road pics.
I'm looking forward to the Yammies birthday too. Especially the sound. Original mufflers are as common as rocking horse turds, so its a toss up between getting something similar made, or making some chambers for it. Either way it will be the sound of the 60-70s (snap, crackle pop!) which is something that's long gone from the urban soundscape. I'm also looking forward to leaving the lights in a cloud of blue smoke, hopefully in front of a Prius.

Kiwialfa
24-02-16, 09:55 AM
Well done my Kiwi friend and keep going as when finished it will be a credit to you for your effort.
Nick

Thanks for your kind sentiments, Nick. Although I'm across the ditch in somewhat splendid isolation, it's comments like yours that reinforce the feeling of being part of our Katana brotherhood. I've been thinking that I'll have to get over and attend an S.K.A. event in Aus at some stage in the future.

peteGSX
24-02-16, 02:53 PM
Cheers Darryl, yeah that satisfaction just cannot be beat! And 2 strokes have a very magical sound and aroma... all to be enjoyed immensely :D

melwain
24-02-16, 10:08 PM
This is such a cool reno. My friend had one of these back in the day and I loved the sound it made and the smell of two stroke oil smoke. If memory serves me correctly it had "megaphone" style mufflers as standard fitment. I think the colour was black frame and the tank was red and white.
Keep the pics coming. I love it!!
Cheers
Mel

Kiwialfa
07-06-16, 08:55 AM
A quick update. I am collecting the final bits and pieces before commencing engine reassembly. Most of the guts in the engine are going to be replaced as the cost of replacing is cheaper than repair, and some bits like gear shifter system, etc. are beyond fixing. Luckily there are folks, usually in the dusty places of the US that have most of these bits (thank you eBay). I'll chronicle the engine reassembly when this happens. I just need to receive the kick start gear before I can begin. I'm going to press the crankshaft back together myself and I'm currently building a truing stand to do this. I'll true each side of the crank separately and then press the 2 cranks together... well that's the plan

So to date, I've resprayed the frame, swing-arm, stands, and battery/tool box in Septone satin sub-frame black and re-bushed the swing arm with brass bushes as opposed to the standard plastic ones. I've begun on the body work filling the small dings, waves and rust scars. Just sprayed some primer yesterday. I'm going to paint this one completely myself using acrylic and have pretty much decided to paint is orange... actually Holden's Tiger Mica, which will be interesting learning experience.

http://i1300.photobucket.com/albums/ag97/KiwiAlfa/Yamaha%20YDS5%20Restoration/20160606_162915_zpsfqxnedda.jpg

Nick Kakasiouris
07-06-16, 09:55 AM
I am looking forward to the finished project and the colour will be striking

ThomasJ
07-06-16, 10:32 AM
I am looking forward to the finished project and the colour will be striking

I am with Nick, cannot wait to see it finished. I vaguely remember the XS650 had simular orange; is this correct? Whatever, this will looking smashing on this bike.

Kiwialfa
07-06-16, 10:52 AM
Couldn't find any original 1967 Yamaha paint codes, and I don't think they offered orange (I think it was red, blue and light green?), but I've always like the orange used on Commodes and orange is a late 60's early 70's colour so in keeping. Purists might tut-tut on a non-standard colour, but I'm not building "as from the factory" I reckon each machine has its own history and rebuilding this sucker and painting it orange is/will be part of this bikes history. As I've said before, I'm still tossing up on modifying some later RD mufflers to fit (if I can find some - expensive), possibly getting a set of replica mufflers made (expensive) or making a set of chambers. As a kid in school I remember this library book of 1970s cafe racers, mostly customised jap strokers some with chromed chambers, and they looked cool. I still marvel that such strong pornography was actually in the school library... Years ago a mate of mine used to make his own chambers for his road racing bike and RD350 Cafe racer. So I know what was involved..... decisions, decisions. Although I'm not building a cafe racer, a flat bar and a set of chambers would be period, and a lot of fun.

ThomasJ
07-06-16, 12:09 PM
all sounds great to me.

Kiwialfa
02-07-16, 03:44 PM
http://i1300.photobucket.com/albums/ag97/KiwiAlfa/Yamaha%20YDS5%20Restoration/20160702_163533_zpsanghejxh.jpg

Home made crank truing stand

Toadboy
02-07-16, 09:31 PM
Nifty... :)

peteGSX
03-07-16, 07:54 AM
Nifty indeed! That's great!

Kiwialfa
03-07-16, 02:13 PM
http://i1300.photobucket.com/albums/ag97/KiwiAlfa/Yamaha%20YDS5%20Restoration/20160703_133335_zpsrdmvekxs.jpg

Pressing in a fresh crank pin

http://i1300.photobucket.com/albums/ag97/KiwiAlfa/Yamaha%20YDS5%20Restoration/20160703_134508_zpsywn4jvrb.jpg

Fresh rod and big end

http://i1300.photobucket.com/albums/ag97/KiwiAlfa/Yamaha%20YDS5%20Restoration/20160703_135325_zpshhr3k5gm.jpg

Half of crank assembled and ready for trueing

peteGSX
04-07-16, 07:25 AM
Nice work! That press must come in so handy...

Kiwialfa
04-07-16, 08:31 AM
Nice work! That press must come in so handy...

Thanks Pete. Yeah the press has been handy. Pushing out bushes, etc. is a breeze. Yesterday I pressed a gear on the Yamaha kick start shaft, I the past I'd have resorted to the bloody big hammer, and probably damaged something. The press was on special when I bought it. My theory, is if I need a tool I'll buy it. If it doesn't get used much you can always sell it in "near new condition". The money you lose is hopefully the cost of the job you were going to pay some else with the right tool to do it for you anyway. Which could also be me justifying my tool fetish. :p

peteGSX
05-07-16, 06:33 AM
Haha that makes perfect sense to me!! Just wish I had the room for all the tools I want...