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1967 Yamaha DS-5 250cc Rebuild

Discussion in 'Your 250cc Projects' started by Murdo, Apr 19, 2014.

  1. Murdo

    Murdo The Good Doctor Staff Member Contributing Member Ride and Events Crew

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    1937 Royal Enfield 250, CF Moto 250 V5, Honda's XL250, CBR250, FT500 plus a few others.
    Bikes and trailer 004.JPG 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.
    001.JPG
    Did a bit of polishing as well.
    007.JPG
    Ready to start reassembly.
    012.JPG
     
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  2. Tim_

    Tim_ resident nutcase Contributing Member Dirty Wheel Club

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    Is that storage or a trophy mounted on you wall?
     
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  3. Murdo

    Murdo The Good Doctor Staff Member Contributing Member Ride and Events Crew

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  4. Murdo

    Murdo The Good Doctor Staff Member Contributing Member Ride and Events Crew

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    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.



    001.JPG
     
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  5. Phil

    Phil Senior Member Contributing Member

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    Now this bike brings back memories, a school mate of mine got one new and he had a good run with it, from memory it was blue. Do they have electric start,can't remember. Look forward to watching your progress with this one.
     
  6. Murdo

    Murdo The Good Doctor Staff Member Contributing Member Ride and Events Crew

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    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.
     
  7. Murdo

    Murdo The Good Doctor Staff Member Contributing Member Ride and Events Crew

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    Got some painting done over the weekend. Had a bit of time today to start fitting some of the painted bits.
    XL100 rebuild 003.JPG XL100 rebuild 004.JPG
    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.
     
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  8. Murdo

    Murdo The Good Doctor Staff Member Contributing Member Ride and Events Crew

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    My Bike:
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    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.
    Bruce bike 016.JPG
    Refaced the instruments with a new sticker to really give it a new look.
    Bruce bike 017.JPG
     
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  9. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    Looking great :thumb_ups:

    Are they the original switchgear and levers ?
     
  10. Phil

    Phil Senior Member Contributing Member

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    They look familiar to me, hey it was a long time ago.
     
  11. Phil

    Phil Senior Member Contributing Member

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    Love your work Murdo, big trip down memory lane. My Suzuki 250 at the time had those rather large covers on each side, I use to cruise over the border into Italy and buy a bottle of scotch and place it under the cover and return to france saving myself around $3.00 a bottle, big saving in those days.
    Can't wait for the next instalment.:thumb_ups:
     
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  12. Murdo

    Murdo The Good Doctor Staff Member Contributing Member Ride and Events Crew

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    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.
     
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  13. Simon

    Simon Well-Known Member Premium Member Contributing Member

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    standing back in awe..that is one crisp restoration..i shall be watching the thread like a hawk for the next instalment..downright gorgeous doesn't even come close..awesome bike m8 :):)
     
  14. Murdo

    Murdo The Good Doctor Staff Member Contributing Member Ride and Events Crew

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

    Simon Well-Known Member Premium Member Contributing Member

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    What i'm looking at is genuine loved for and soon to become cherished bike..no nos required i'm looking at some of your polished stuff now..if only I knew how..not much good with a dremel polishing kit never mind getting even close to that standard of finish that you've already attained..any advice on alloy polishing gratefully received..chrome usually gets re chromed but what your doing gives us all an insight on a limited budget as to what you can actually achieve..I see where your coming from though with the detail that 'makes the bike' in mind..one day..my old man had one years back..its long since gone now..but i shall show him these pics next time he comes home from the middle east to retire..it'll truly bring back memories and make his day..great to see another being returned to its former glory..hats off mate and keep up the good work:)
     
  16. Simon

    Simon Well-Known Member Premium Member Contributing Member

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    ..murdo..quick question for yus..distinctly remember the exhaust being very high..almost level with the rear shocks (or not far off level with the cylinder head)..on a flat plane through the entire length of the bike..the number of burns I got on my inner legs as a five year old at the end of the seventies would of brought the child protection agencies out in this day and age lol..is yours the original exhaust or was my old mans an earlier or later version..he swears blind he'd had it for ten years before I was born but that puts it 65 or 66 ish..and from recollection it was far to new even then for it to be anywhere near that age!!!! Any advice greatefully received and dully passed on!

    Cheers si
     
  17. Moo

    Moo Plodge Racing!!!

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    wow mate, i'll be glued to this one!
     
  18. Murdo

    Murdo The Good Doctor Staff Member Contributing Member Ride and Events Crew

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    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.
     
  19. Murdo

    Murdo The Good Doctor Staff Member Contributing Member Ride and Events Crew

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    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.
    seat repair 005.JPG
    I made a 'jig' to hold the seat straight while I cut out the rusty bits and welded in new metal.
    seat repair 008.JPG
    seat repair 010.JPG
    seat repair 011.JPG
    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. :thumb_ups:
    seat repair 015.JPG
    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.
     
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  20. risky

    risky risky

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    i am jealous
     

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