Thumper Club Forum
Technical => Project Progress => Topic started by: Helen on April 21, 2007, 10:38:51 AM
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Hi
I'm trying to reconstruct my SR500 which is in a zillion pieces. The bike was my only form of transport some 20 years ago and was taken off the road as the little end was worn oval. I stripped it all down ready to sort out about 15 years ago and it's been in boxes ever since!
I have a couple of things I need help/advice on to get started if anyone has any ideas please (any there will probably be loads more questions to come!)
1. Should I try and get hold of a new conrod and get the crank split and replace it? If so, where can I get one from? Are these still available somehow or am I being a bit optimistic here?
2. Is it possible to just get the conrod bored out and have a sleeve put in it?
3. My front wheel and mudguard have disappeared somewhere along the way. Can anyone recommend a breakers that deals with old stuff like this? I live in Notts, but I don't mind travelling a way if necessary.
4. The seat needs re-covering (and a bit taken out of the front as I've only got little legs and my original seat with a bit taken out has also gone astray).
Thanks
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Hi
I'm trying to reconstruct my SR500 which is in a zillion pieces. The bike was my only form of transport some 20 years ago and was taken off the road as the little end was worn oval. I stripped it all down ready to sort out about 15 years ago and it's been in boxes ever since!
I have a couple of things I need help/advice on to get started if anyone has any ideas please (any there will probably be loads more questions to come!)
1. Should I try and get hold of a new conrod and get the crank split and replace it? If so, where can I get one from? Are these still available somehow or am I being a bit optimistic here?
2. Is it possible to just get the conrod bored out and have a sleeve put in it?
3. My front wheel and mudguard have disappeared somewhere along the way. Can anyone recommend a breakers that deals with old stuff like this? I live in Notts, but I don't mind travelling a way if necessary.
4. The seat needs re-covering (and a bit taken out of the front as I've only got little legs and my original seat with a bit taken out has also gone astray).
Thanks
hey, glad to hear ya wanna get her running!
i always order parts from the yamaha dealership in glasgow, im not sure if they can deliver but they do pretty much everything for every yamaha ever built!
theyre called "ride on" try giving them a buzz on 0141 423 2773 and see if you can get a new conrod.
ebay is a good place to look for mudguard etc also check out the links at the bottom of this page: http://www.motorcycle.co.uk/lists/PartsClassic.html
peace
Damo
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Hi Helen
Welcome. Sorry I cannot help with the questions, just wanted to say Hi and welcome to our happy band. As to the conrod I would be inclined to seek out a replacement - either Yamaha or a pattern part if available - rather than get the one you have bored and bushed.
Are you looking to build a perfect SR500 - except for the cut down seat - or are you happy to mix and match - it may be that the front wheel / front end from another Yamaha will do a good job and be more available - I do nto know but I bet someone here does.
R
Look forward to seeing pics
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Hello!
Thanks for your replies - the bike doesn't need to be original. As long as the front wheel looks reasonably similar to the back one that'll be ok.
Helen
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I had an NX650 conrod bushed some years ago (due to a blow up - it had 'picked up') and the repair is still performing its function perfectly.
What was the better, the engineer did it with the crank still in place in the cases.
Cheers
GC
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That's interesting - I'd assumed it the crank would have to be spilt for the conrod to be machined. Was it expensive? I have been quoted about £100 for a new conrod (thanks for the phone number Damo!) then it would have to be fitted to the crank as well....
Helen
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As Graham says it possible to have the little end bushed, and some engineers will do it without stripping the engine. I rememeber a conversation years ago with a machinist who was explaining how he machined the littles ends in situ, I scratched my head for a while and asked about all the swarf generated. Aha he said very I have a very special tool made by tesco's, and he pulled out a plastic bag. Obvious really.
As for the wheel you may find XS650 parts fit, a common conversion is to use an XS650 front end to get a twin disc setup
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Well that told me...
That is the good thing about the peeps on here - never worried about helping a guys education. So ignore all I suggested and seek out an engineer to re bush the eye with the crank in situ - sounds like a much better outcome to me.
R
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Hmmm.... yes, now I'm really beginning to wish I hadn't removed the crank from the engine all those years ago...
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I have to add if the ovality is really bad and you take a lot of material out to correct it, it goes without saying that you risk weakening the conrod in the little end area which can have naughty concequences. But thats for the engineer that does the job to assess/decide if its viable...
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Any reduction in strength from bushing could be more than compensated for by a small lowering of the redline. My memory of SR's tells me that chasing the redline wasn't a very enjoyable experience anyway. You aren't looking to build the ultimate performance SR are you?
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If its oval you have to be quiet carefull that you find the original centre before you bore it out. I dint know for sure but you would expect a conrod to be made of quiet hard material and so had to work on . Maybe you could have it honed out along with the piston and fit a slightly larger gudgeon pin.
Just a thought
Ken
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Hi Ken
Looking at the gudgeon pin, it's only showing wear marks on one half (it's slightly burred) so I'm assuming that the wear in the conrod is also just on one side, so maybe not too hard to find the original centre?
PS Please excuse any mechanical/terminology gaffs I'm making here guys - it's ages since I've looked inside an engine!
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Use the correct technical terms and no one will know what you are going on about - well the sad few will. Describe what you see and the rest of us will think - Ahh I know that.
"Thingy" - the correct technical term for any part for which you are unsure of the function.
"Widget" - a complex looking "Thingy"
"Sticky out bit" - and "Thingy" that sticks out.
"Sticky in bit" - any "Thingy" that sticks in.
Not to be confused with a "Bit Sticky Thingy" - this is any bike part handled by a 4 year old who has been eating sweets.
"Fettle" - to take apart and rebuild in the hope that it will now work better.
"Buggered" - any mechanical device Roger has "Fettled"
"Mullered" - any mechanical device Roger has tried to repair.
R
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The very first TC newsletter had a glossary of biking terms. My favourite was:
Sidestand - a device for poking deep holes in soft ground.
GC
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Now then, does anyone know anything about raceline oil line kit thingy bobs for these? I remember something about overheating problems and it being a good idea to have one (I know I'm getting ahead of myself here - it's still in a zillion pieces, same as last week....)
Could my engine problem be down to not having one? A while before this I had to have new camshaft bearings.
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If you look at the 'Fuelling problems..' thread in 'Bike Problems' on this forum, Damo is having similar issues. I know nowt about these bikes but theres been some info and links posted about the oil line mods.
Dave b
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Thanks - I've just had a look - that's really helpful.
Helen
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An addition to that... from last trip to the TT on the Triton.
Sidestand - a device on the bike that allows you to prop it up away from lampposts, but will fail when you are too far away from bike to catch it.
Helmet - a device to stop you bike from hitting the ground and denting the ally tank when the 'sidestand' fails on cue.
Footrest. A device to stop bike sliding from helmet, it achieves this by punching a neat hole through said helmet
R
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or.. 'sidecar' the bit you usally hit in a 'sorry mate, didn't see you' scenario
With regard to your seat (i refer to the one on your bike of course!)
I use a chap in Kings Lynn, who does a good job (see my SRX's #1 & #3 in piccy section somewhere)
he can do almost any shape or style you want, but would obviously need a drawing and instructions
and colour required.
steve
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Use the correct technical terms and no one will know what you are going on about - well the sad few will. Describe what you see and the rest of us will think - Ahh I know that.
"Thingy" - the correct technical term for any part for which you are unsure of the function.
"Widget" - a complex looking "Thingy"
"Sticky out bit" - and "Thingy" that sticks out.
"Sticky in bit" - any "Thingy" that sticks in.
Not to be confused with a "Bit Sticky Thingy" - this is any bike part handled by a 4 year old who has been eating sweets.
"Fettle" - to take apart and rebuild in the hope that it will now work better.
"Buggered" - any mechanical device Roger has "Fettled"
"Mullered" - any mechanical device Roger has tried to repair.
R
I'm familiar with this terminology. I can see all these parts in my minds eye as I work my way around my bike.
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Hi Helen,have you had any luck with the conrod?My XT350 seems to have a similar problem and I am also in Notts.
Cheers Dave
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Hi Dave
Well, I've ordered a new gudgeon pin which should arrive this week. If it does, we'll take the conrod & gudgeon pin to Service Engineering in Grimsby (my hubby goes that way quite often) on Friday to see what they can do with it.
I'll let you know how I get on!
Helen
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I've decided to have the conrod replaced. I've been advised that there isn't much metal there to work with and having it honed out would weaken it. I reckon that with it being the one and only, it needs all the strength it can get!!
So I've ordered more bits & pieces and it's plan B now. I'm going to try SEP in Kegworth for this....
Helen
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I'm going to try SEP in Kegworth for this....
Ive not used them myself but have heard good things about them
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Thanks, that's reassuring to know.
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Helen,can I ask where you ordered your parts from?Living out in the sticks I don't want to be back and forth too many times fetching stuff from dealers if I can help it.
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Hi Dave
I've ordered them from Jeff Hall Motorcycles in Sheffield (0114 2333116). Although they're not Yamaha dealers, they've been really helpful so far. Ask for Kevin - he'll do his best to find what you need.
Good luck!
Helen
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Hi
Amongst my many parts in boxes is a brake caliper, without piston or any of the other bits & pieces. The thing is, I don't know if it's the right one (for instance, there are some Honda CB500T bits in there). Would someone be really kind and post me a photo of the correct one for the bike so I can identify it please? Just a snap of the caliper on the bike would be brill.
Thanks,
Helen
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Come on guys - help the lady!
R
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Would a parts list help ?. I have one on PDF
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Heres a couple of pics from my stock 1980 SR500. hope they help. If you want bigger pictures or pictures of any other part of the bike, or any SR500 specific questions just ask.
(http://i85.photobucket.com/albums/k62/saltmason/DSC00726.jpg)
(http://i85.photobucket.com/albums/k62/saltmason/DSC00725.jpg)
Damo
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Thanks - hurray - it's the right one! (but thanks Steve)
The Haynes manual only shows the other side of the bike.
Further to the original thread -
- I now have the engine built upto the barrel. I keep having to stop and wait for the odd part to arrive, which is quite frustrating, but it's getting there slowly.
- SEP were brill, and cleaned my crankcases up for me as well.
- Trophydave - I've been getting bits from The Bike Depot in Worksop instead recently - is this any closer to where you live? (They get their Yamaha parts from Fowlers in Bristol I think, and most things take about a week to arrive)
Helen
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I am in Bingham,not a million miles away from Worksop.I would rather use a 'proper' bike shop than one of these corporate franchise dealer places.Saying that I have a mate with a small breakers,I ought to try him first really.
Confession time.I stripped the XT350 after Wetton to investigate the lack of go.All I have done since is give the barrel a light hone to try and clean it up a bit and that is it.I am using the VFR at present but I am slowly negotiating the purchase of a Transalp from a friend.
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How did you get on wth this helen?
Damo
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Hello
I'm pretty sure I have all the right bits for the front brake now, but I haven't got as far as fitting it (only just put the forks in) so time will tell. It's all slowed down a bit recently - I need to pick up the pace again!
Helen
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Haha, yeah get it all shiny and sounding sweet for summer '08 (http://www.fzrarchives.com/ipb/style_emoticons/default/banana.gif)
keep us posted :)
Damo
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I have my bike mot'ed at the bike depot.
They are what I call a, proper bike shop. Usually lets my bike through no problem or fixes on the spot. ie no back reflector so he stuck one on for a £1. He is also good with loud exhausts, as long as you are discrete.
They are about 5 miles from where I live and have existed for quite a few years.