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Official YZF Makeover Thread

Thanks everyone for the words of approval! Today was a great day to say the least. I just dropped off Irene after a great evening of dinner, good wine, and a DVD!......and yes, that was it! Haha! It was so nice to have another human being other than myself or Richie here in the house. The dog was freaked out and didn't know what to do! Haha! He finally settled down and enjoyed the company. It's time for me to hit the sack. We polished off a 2 litre bottle of Bearfoot, which was great by the way, so I'm ready to sleep it off until tomorrow. I have some work to do in the garage!!!! Yeah baby!!!
 
Just got upstairs from working on the bike with Richie today. What I wanted to accomplish: Remove Tube From Gas Tank, Straighten out the tail section, License Plate Bracket, Clutch Bleeding (Catastophy!), plugging the EXUP screwhole, and installing bodywork. Simple enough hey?!

Okay so let's get started! Richie had a keen eye and plucked out the petcock tube from the tank with my grippers! Yeaaaa!!!
IMG_3177.jpg


Okay, tail straightening! This was how "off" it was before I finished:
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I was convinced that this bike was never "down" ever, so there had to be a reason for this "kink". I rigged up a long section of steel pipe and bolted it to the rear section of the frame.
IMG_3180.jpg


You get the idea hey?
IMG_3181.jpg


Now after me and Richie pushed and pulled, yanked, and everything else, we couldn't see progress. Just on a whim I decided to remove the passenger peg bracket on the exhaust side and BINGO!!!, the tail section released and immediately settled a full half inch to the left!
IMG_3183.jpg


I told Richie to dig through my stuff and find me some galvanized washers. I used three on the forward bolt and two on the rear in addition to the bracket to make up the correct spacing. I then pushed the exhaust over the remaining 1/4" and bolted it back together. The tail was back perfect!! I slapped on the new plate holder and look at the difference!
IMG_3186.jpg


I mixed up a batch of JB Weld and plugged the hole in the EXUP cover to stop the exhaust leak.
IMG_3184.jpg


Next up was the Clutch Bleeding. The fluid in the Master Cylinder was BLACK!!! I removed it all but not by evacuating the system first. I just kept adding new fluid and then bleeding until I was getting "new" fluid from the bleeder. The problem was that I was only getting air for the entire time! I mean, it was filling up the reservoir but with a ton of air. I refilled the Master about 7 or 8 times so I thought I was done. No more dirty fluid. I finished up and felt the lever as normal as ever, but now I have no clutch!?? I had to move on cause Richie wanted to get the bodywork back on. I'll wait to get more info since I have never bled a hydraulic clutch before so I must be doing something wrong.
The new fluid looks great. Too bad it doesn't work!
IMG_3187.jpg


Bodywork Time!!! I did the rear tail section. Looks straight as heck now!
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IMG_3190.jpg


Richie did all the other panels except the nose which I brought upstairs for cleaning.
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So everything except the clutch went great. The new stock turn signals look awesome as does everything else. I decided the roll it outside to see if she would start up as fast for me as at Ivan's. I wasn't disappointed! In the video you can see the time I start her up and at what time I turn the choke completely off. It just sounds great but then I remembered the JB Weld had to cure so I shut her down.

[ame=http://www.youtube.com/watch?v=i7LQVIF49Lg&list=UUtIiPrXXOnkIUMfJ6mRxgkQ&index=1&feature=plcp]YZF Cold Start - YouTube[/ame]


So I have to clean the nose section up and figure out how to bleed the clutch properly and I'll be all set!
 
Great job Billy! So, the peg/exhaust bracket is what is out of shape? And it was pulling the sub-frame out of alignment? Where else is that bracket attached to that is more solid than the subframe? Hmmm... Source a new set of those? ;)

She's looking very good now and sounds excellent. Well done!
 
FZ1inNH said:
Great job Billy! So, the peg/exhaust bracket is what is out of shape? And it was pulling the sub-frame out of alignment? Where else is that bracket attached to that is more solid than the subframe? Hmmm... Source a new set of those? ;)

She's looking very good now and sounds excellent. Well done!
Click to expand...

No, it's actually the stock exhaust period. I'm assuming that with the full exhuast that was on there, they must have removed a spacer or bracket to use with the Vance and Hines system. So it was "pulling" the entire tail section over to the right. As soon as I unbolted the passenger bracket, the entire tail section jumped right over into proper alignment, the exact 1/2" that was off to begin with. So I just spaced it with washers between the passenger bracket and frame and that was that. It was pretty cool!
 
FZ1riderNY said:
No, it's actually the stock exhaust period. I'm assuming that with the full exhuast that was on there, they must have removed a spacer or bracket to use with the Vance and Hines system. So it was "pulling" the entire tail section over to the right. As soon as I unbolted the passenger bracket, the entire tail section jumped right over into proper alignment, the exact 1/2" that was off to begin with. So I just spaced it with washers between the passenger bracket and frame and that was that. It was pretty cool!
Click to expand...

Usually, I like to be right but this wasn't one of those. ;) When I first mentioned it, I hated to because it's sometimes a bigger issue, but in this case, it was something easier to fix and I'm very happy you got it straightened out. The exhaust is THAT strong, eh? To pull everything else out of whack.... wow!!!
 
FZ1inNH said:
Usually, I like to be right but this wasn't one of those. ;) When I first mentioned it, I hated to because it's sometimes a bigger issue, but in this case, it was something easier to fix and I'm very happy you got it straightened out. The exhaust is THAT strong, eh? To pull everything else out of whack.... wow!!!
Click to expand...

Well, only because there is another rear bracket bolted to the rear of the oil pan which the exhaust bolts into as shown in the photo below.
IMG_3170-1.jpg


That mount is directly bolted into the engine and can't be moved, so when the exhaust is bolted in there it isn't budging! Also, I have to say that when I had the steel pipe bolted onto the frame, it wasn't that hard to see it bending very easily. It's all hollow aluminum.
 
Wow Billy, You've made some progress there. It looks great too! So glad the rear end turned out so well in the end! (pun intended) :D
Sound awesome too! Reminds me of my YZF years ago... I miss that bike..
Happy trails brother! :tup:
 
Billy,

When a hydraulic Clutch just suddenly quits working it is very often the "O" ring inside the clutch slave. This happens , and is a well known issue, on the clutch slaves on my 990. It could be that in flushing the old fluid out the "o" ring just finally gave up. If that is the case, better while you are in the garage than out on a ride. It is fairly easy to fix and really only the cost of the parts and more fluid. I am sure if you don't have the schematic, Tony will. If it is anything like mine it will be the "O" ring on the slave piston, but you should probably get a new snap ring (that holds the piston in place) as well.

If that isn't the problem than it may need a master cylinder rebuild.

Just throwing ideas out there.
 
Oldschool said:
Billy,

When a hydraulic Clutch just suddenly quits working it is very often the "O" ring inside the clutch slave. This happens , and is a well known issue, on the clutch slaves on my 990. It could be that in flushing the old fluid out the "o" ring just finally gave up. If that is the case, better while you are in the garage than out on a ride. It is fairly easy to fix and really only the cost of the parts and more fluid. I am sure if you don't have the schematic, Tony will. If it is anything like mine it will be the "O" ring on the slave piston, but you should probably get a new snap ring (that holds the piston in place) as well.

If that isn't the problem than it may need a master cylinder rebuild.

Just throwing ideas out there.
Click to expand...

Thanks Lee. I doubt that anything is wrong except I'm not bleeding it correctly. I'm going to try the "oldschool" method, no pun intended, when I get home today from work. They told me that if the o-ring was bad that I'd have oil on the floor but everything is dry. I just keep getting air.
 
Oldschool said:
Billy,

When a hydraulic Clutch just suddenly quits working it is very often the "O" ring inside the clutch slave. This happens , and is a well known issue, on the clutch slaves on my 990. It could be that in flushing the old fluid out the "o" ring just finally gave up. If that is the case, better while you are in the garage than out on a ride. It is fairly easy to fix and really only the cost of the parts and more fluid. I am sure if you don't have the schematic, Tony will. If it is anything like mine it will be the "O" ring on the slave piston, but you should probably get a new snap ring (that holds the piston in place) as well.

If that isn't the problem than it may need a master cylinder rebuild.

Just throwing ideas out there.
Click to expand...

Very possible that the slave cylinder gave out (or the master cylinder). Either one is easy enough to rebuild. I ended up rebuilding my slave cylinder as a precaution when I put my YZF together. No special parts needed other than the rebuild kit:

YAMAHA YZF1000R 1997 CLUTCH SLAVE CYLINDER REPAIR KIT | eBay
 
FZ1riderNY said:
No, it's actually the stock exhaust period. I'm assuming that with the full exhuast that was on there, they must have removed a spacer or bracket to use with the Vance and Hines system. So it was "pulling" the entire tail section over to the right. As soon as I unbolted the passenger bracket, the entire tail section jumped right over into proper alignment, the exact 1/2" that was off to begin with. So I just spaced it with washers between the passenger bracket and frame and that was that. It was pretty cool!
Click to expand...

Billy I wonder if that stock exhaust pipe is somehow bent a little. By the way I have a "spare" bracket if you want to try it on just in case yours is somehow bent, but I doubt it.

Oh and the bike sounds great after Ivan did his magic. I'm sure it's going to run fantastic once you finally get it on the road :)
 
NJFZ1 said:
Billy I wonder if that stock exhaust pipe is somehow bent a little. By the way I have a "spare" bracket if you want to try it on just in case yours is somehow bent, but I doubt it.

Oh and the bike sounds great after Ivan did his magic. I'm sure it's going to run fantastic once you finally get it on the road :)
Click to expand...

Thanks Tony. To me, it doesn't look as if the passenger peg bracket is bent or anything. It looks as though I'm missing a spacer or something. There is a bracket on the Vance and Hines pipe that I didn't transfer over to the Yoshi. That bracket has an "offset" bent into it which I bet would make the difference in space. It's just that when I opened the Yoshi, it had all the hardware for it in the box so I never used that original bracket. Also, I did feel that the midpipe section looked a little close to the swingarm originally but I had no pics or anything to gauge it by so I figured it was the stock location. With the three washers behind the bracket, it fits perfectly and everything looks in line as you can see in the picture.

Oh and yes! It was Magic! You were there and started it for yourself. You literally need 5 to 10 seconds of choke and shes idling by herself. It's amazing the way it feels. Very responsive at the throttle. I'm super happy with the outcome!
 
bled the hydraulic clutch on the Ninja with JOTR's mityvac and it only took just a couple minutes.I couldnt remember what tires you put on Billy what are they Bridgestones?
 
Hey bud...sorry I haven't maild the decals been super busy and then forgot....they are in the truck for mail tomorrow ...with a couple other decals I cut for ya...

Sent from my EVO 4G using Tapatalk
 
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