1967 Yamaha DS-5 250cc Rebuild

Have started on the restoration of my YDS-5. I bought it about 18 months ago with some others from the local scrap metal bloke, he was going to crush them! Have been slowly getting some bits together and have enough now to start on the rebuild.
It was built in 1967 and is a low serial number bike, with engine and frame matching numbers. I don't think that it has been stripped before (maybe barrels off) as everything looks to be in original position.
I have been surprised at how easily it has come apart after 47 years. I have not had to use an impact driver yet, all the screws have been undone with a screwdriver. The engine bolts were still greasy from the original installation and wiring still tagged to frame. The engine cases have to be split to replace seals and kickstart shaft, but it still has good compressions. The wiring will need some attention due to PO attempts to fix something. The exhausts will need a clean out as it had 4 stroke motor oil in the oil tank when I got it home and they are pretty well carboned up at the ports.
The frame is painted.

Did a bit of polishing as well.

Ready to start reassembly.

 

Tim, see my earlier thread 'Murdo's Museum'.

http://2fiftycc.com/index.php?threads/murdos-museum.2000/

No trophy's yet.

 

Had a productive day today. Have found the wiring problem that PO tried to fix. Some how the top of the voltage regulator had been dented, and when the arm moved up to shut off power it touched the metal case and caused a dead short to earth, melted wires and plugs being the result. Will have to wait for the shops to open on Tuesday to get the heatshrink I need to fix it.

 

Yes Phil, they came in blue and red (mine). The electric start is part of the generator on right side of cases. It is two of the wires from there that are melted, so fingers crossed that the stator is ok.

 

Got some painting done over the weekend. Had a bit of time today to start fitting some of the painted bits.

Although the pictures don't show it very well it is a bright metallic red (Diahatsu mica red), as close as I could get to the original candy apple red in a COB (clear over base) acrylic.

 

Have spent quite a few hours getting electricity running as it should and now, hurrah, it all works. Fitted new tyre, wheel bearings and overhauled the brakes and fitted front wheel. Now to start on the back one.

Refaced the instruments with a new sticker to really give it a new look.

 

Yes Grey, they are all the original pieces, just rebuilt and polished.
Having so many of those original bits it what decided me to restore this one. Plan to get all the rolling gear done before starting on the engine as it has to be split to get the chewed up kickstart shaft out to built up with weld and respline. Will be fitting new crank seals and other bits as required when I get it apart.

 

Thanks Simon. Wish I had the money to buy all the new old stock I find, it would be even more gorgeous.

 

Thanks for the kind words Simon.

Re polishing; I use a 200mm cotton mop on the end of my bench grinder, and the medium pink buffing soap. These I bought from Gasweld, but Bunnings sell them too. It is a **** of a job as the soap and bits of cotton get flung everywhere, your hands are covered in black crap and your clothes too. I wash the bits first to clean off any grease, and those with old clear lacquer or corrosion are softly glass bead blasted (50psi) to clean the surface. Any that are scratched will need a wet sanding with 600 wet n dry, then polish with sisal mop (tougher stringy one) to get a good surface then with the cotton mop. Boring job but the reflection of my smile is worth it. I also buff up the chrome bits that are still ok (look at the fork legs) but some will have to be redone.

Re the high pipes; this would have been a street scrambler version. They were introduced in 1960-61 and had chunkier tyres, high pipes, sump guard and high or raised front mudguard.

 

Have a bit more done. I have decided that due to this being a bad time financially, I will just buff the chrome pieces as best as I can and will get them redone later.
Had to do a bit on the seat.

I made a 'jig' to hold the seat straight while I cut out the rusty bits and welded in new metal.



A clean up, coat of paint, new foam and cover and its ready to fit. Had to build up the foam with layers of hi density foam as the original had rotted years ago, which is why the seat rusted. I had nothing to copy so I kept building up until it fitted the new cover, and looked similar to the pictures. It was a very messy job and at one stage I think I had more glue on the bench, the brush and me than on the seat. Let dry overnight and fitted the cover this morning. Looks like it was a factory job.

Fitted the tank (tempory) and the seat snuggles up to it nicely. Now all it needs is an engine, but will not be starting on it for a couple of months due to other things waiting for my attention.