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Project The Yamaha R4 (Glacially Slow Project)

Discussion in 'Other Projects - Other Bikes (non 250's)' started by maelstrom, Dec 20, 2014.

  1. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    So I bought a pair of Chinese discs that have black alloy centres.
    R4_FrontDiscs.jpg
    and since my old disc rotors are still quite usable, I bought a set of rotor buttons from the UK. When the Chinesium discs wear out I will swap the rotors.
    DSCN4633.JPG
     

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  2. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    So here is the lower case after vapour blasting.
    L_Case_01Untitled.jpg LowerCase_07.jpg
    To prepare, I taped the surfaces with aluminium tape and used grub screws and silicone plugs for most of the rest.
     
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    Last edited: Oct 17, 2019
  3. kiffsta

    kiffsta Administrator Staff Member Dirty Wheel Club Contributing Member

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    Looks great, well done, are you doing the top case ?
     
  4. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    Yes, but I didn't have enough plugs to do both at the same time.
    I think it might be noticeable if I don't do it. :)
    BeforeAfter.jpg
     
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  5. Tigger996

    Tigger996 Active Member

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    My Bike:
    Yamaha-Fzr250-3LN-EXUP 1989. Yamaha FZR400, Ducati 998S & 996 & 900SS & ST4. Dresda Triton. Suzuki T500 road & T500 race. RS125 with Rotax 257 engine. and a couple of Ossa trials bikes in bits and a Sachs rolling chassis
    Love looking at other riders projects. I have the problem of starting the next one before finishing the last one.

    Projects on the go.
    1. Dresda Triton T140, needs a few lugs cutting off and dismantling for paint(started 2010)
    2. Rotax 250cc 50bhp at the wheel 2 stroke engine into Aprilia RS125, needs assembling just to see what's missing.
    3. Race Suzuki T500 just needs timing and Lectron carbs tuning in.
    4. FZR400 neaten up and get to start.
    5. Greeves with Norton wheels, Silverstone tank and Triumph 500 engine. Creating a replica of the Greeves Silverstone with a methanol race 500 unit engined bike that put me through a barbed wire fence during a hillclimb. Result, plated ulna and radius with six months in plaster.
    6. Tiger 110 engine with Morgo barrel, T140 inlet, E3134 exhaust.
    7. SR46 (Seonag Racing FZR400/FZR600 hybrid). In the process of fitting R6 alloy rear subframe, bandit rear wheel, remaking brackets in alloy, replacing all bearings, making alloy tanks etc before adding the 600 engine.

    Laziness, two different cancers(now not a problem) and recently a month in hospital for something that the doctors still haven't diagnosed hasn't helped. But main cause is 14 year old brain in a 68 year old body.
     
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  6. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    Holy crapamole Mr Tigger that is a great list. I hope you have a factory to keep them all in. What you need to do is find some young fella who loves playing with bikes and get him to help you out. Who is going to ride all these bikes?
     
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  7. Tigger996

    Tigger996 Active Member

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    When finished they will be ridden either on the road or sprinting. I will still ride my 998S on the road and my 64 year old wife will ride her blue printed 996. The thing about a project is that it is your ideas being translated into an object so you really don't want help, unless it is expert machining etc. I have a friend well into his eighties who has about 110 bikes (one of his racers is the only example left) and he would not dream of having help. Bikes keep you young.
     
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  8. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    Kudos to Tyga
    We recently went down south for a break and popped in for a social/business trip to Tyga. While there I ordered a glass front guard for the Yamaha, and damn, it is a fine piece of work. Light, beautifully made, fine curves with no excess resin anywhere. If you need some bodywork and they have it then you would be hard pressed to find anything better than this. By the way, this is the only piece of bodywork that I can actually just bolt onto this bike.
    R1_FrontGuard.jpg
    TygaGlass.jpg
     
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  9. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    Put the wheels on. Still a billion things to do but for now I will focus on getting the engine in. It might not look much in the pic, but in real life it is something to behold, and I am very happy with it.
    R4_WithWheels_01.jpg
     
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    Last edited: Nov 10, 2019
  10. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    Top case is back from wet blasting. A few motley bits but without doing a dry blast first you have to expect that. I doubt this engine has been cleaned in 30 years. I also bought a high pressure water blaster so I can blast out all the oil galleries with soapy water.
    DSCN4742.JPG
     
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  11. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    Like @kiffsta, I also had a broken M6 to deal with that was heavily Loctited. Removed with my weapon of choice, a Ridgid 35535 parallel screw extractor. It does not expand the screw as you try to remove it and the grip-nut can be slid right down onto the top of the screw. I cannot recommend these highly enough.
    RidgidSE.jpg
     
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    Last edited: Nov 16, 2019
  12. Murdo

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

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    And don't forget the rifle brushes up and down those galleries.
     
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  13. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    Great idea Doc :)
     
  14. Murdo

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

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    I use .17, .22, .30 caliber and 20ga shotgun brushes with plenty of strong soap/detergent and hot water.
     
  15. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    Cases are clean. I used my small bottle brushes but since every orifice was sealed before blasting there has been no unpleasant surprises. I sprayed inside and out with ACF-50 (the HVLP spray gun I bought to do Cerakote has its uses after all) and then positioned all the top case screws to test the threads and make sure they are all accounted for. I am going to assemble the cases with Loctite 518. I like it, it gives plenty of time in case something goes wrong, and being anaerobic it won't leave anything inside the engine. Of course there appears to be some hose/cable brackets missing, no doubt I put them somewhere safe.

    Cases_R4_01.jpg
     
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  16. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    Engine Details:
    I know this is being a bit anal but it could be useful for novices, so I stick it in.
    First up is the crankcase breather baffle plates. The OEM screws are the Phillips style and horrible so I replaced them with low head cap screws. The OEM cross-recessed pan head screws (what most people think are Phillips) have a height of 3.9mm and the low heads are 4.0mm, so close enough.
    LowHeadCapScrew.jpg
    BreatherBafflePlate_01.jpg
    Next is fitting the main bearing and gearbox oil feed restrictors, 2 of each. If you plan to media blast your cases then remove these first and replace with grub screws before taping off. I applied some Loctite before fitting them back in. If you missed it I have done the oil feed mod for the main bearings. See here https://2fiftycc.com/index.php?threads/big-end-oil-gallery-mod-for-fzr400s.10366/
    MainBearing_Restrictor.jpg
    GearboxRestrictor_01.jpg
     
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    Last edited: Nov 22, 2019
  17. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    Oh no you didn't! Oh yes I did!
    hFR7Mc1558064086.jpg
    Genuine 3TJ6 FCR's. Have to bore out the restrictors and rejet of course.
     
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  18. ruckusman

    ruckusman Well-Known Member Premium Member Dirty Wheel Club

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    How many $$?
     
  19. kiffsta

    kiffsta Administrator Staff Member Dirty Wheel Club Contributing Member

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    I have always wanted a set for a mc22 , but when the carbs costs more than the bike , I had to draw the line

    are they used or new ?
     
  20. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    Used, 755 in AUD
     
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