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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. kiffsta

    kiffsta Administrator Staff Member Dirty Wheel Club Contributing Member

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    Bargain
     
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  2. ruckusman

    ruckusman White Mans Magic Master Premium Member Dirty Wheel Club

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    That price is going to have to have an interesting story which accompanies it
     
  3. beano

    beano Well-Known Member Premium Member

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    No better man to fix them though :lolsign:
     
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  4. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    I will make an airbox for them so no need to worry about the restricted fittings. Now I want to find a suitable generic paper air filter element. Maybe this one might do. Toyota 17801-0Y040
    s-l500.jpg
     
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    Last edited: Nov 24, 2019
  5. ruckusman

    ruckusman White Mans Magic Master Premium Member Dirty Wheel Club

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    I've still got the air filter out of my '05 Gixxer 750 - it's washable I believe and could possibly be suitable dimension and now that I think about it, the air filter out of my 99 Subaru was rectangular

    Do you know the dimensions that you will likely require?
     
  6. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    I think that Toyota one will be fine and they are cheap, even genuine. Comes from car that produces 100hp so has to flow enough air for my purposes. I can 3D print the parts and lay CF over them or something similar. If I design the airbox so that it is 3 layer construction, the middle layer can be made different heights to change volume. Then I might be able to put it on a dyno to test that.
    ToyotaAirFilter.jpg
     
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  7. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    Look here's another set. This from what must have been a pristine 3TJ6. This guy just buys really good, classic models and wrecks them. https://www.jauce.com/auction/l563243381
    i-img640x480-15745608177fi9ap301509.jpg
    Trouble is, how do you get them out of the country.
     
  8. ruckusman

    ruckusman White Mans Magic Master Premium Member Dirty Wheel Club

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    Interesting, in that photo you can see the casting - are you going to source new front flanges without the restriction for yours or modify the one that are on there and weld some new tubing in place to complete the section?
     
  9. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    Could just throw them away and fit velocity stacks. No, that would be naughty and very loud. I am thinking about this at the moment. Maybe two options:
    1. Design a rubber velocity stack like FCR blue ones but have a double lip on the outside to seal into the airbox base.
    2. Make the airbox base to fit onto the carb mouths and screw the velocity stacks inside the airbox.
    VS-001.jpg
    Carbs will arrive early next week so i can choose which way to go.
     
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  10. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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  11. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    The OEM airbox rubbers from the 3TJ1 are at least 100mm so I want to keep as much length as possible. Don't want to pay the stupid money that people want for their bits either.
     
  12. ruckusman

    ruckusman White Mans Magic Master Premium Member Dirty Wheel Club

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    OK light bulb moment - those restrictors are on the intake, how I didn't see that clearly the first time is somewhat concerning - clearly there's heaps of options available to you
     
  13. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    Litetek custom 3d printed Nylon intake's sound's like the go.
     
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  14. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    Once I open the roll of Nylon I also want to use it to print four other parts before it absorbs too much water and I have to fart about drying the stuff (hint, hint).
     
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  15. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    Speaking of bargains.
    https://thai.webike.net/en/sd/1355313
    134952 THB = 6579 AUD
    The seller owns a shop in Bangkok and he brings in container loads of bits and bobs from Japan. Apparently someone wanted to fit these to something and it was beyond them or some such.
     
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  16. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    Notice how the JB kit has a long intake runner that I assume fits into the standard 3TJ rubbers. The 3TJ6 has normal length custom rubbers and has the extension on the air cleaner side (the part with the restrictor). Thus my velocity stack/air cleaner box thingies will need to be quite long or on the end of adapters.
    fcr_354_s.jpg
     
  17. ruckusman

    ruckusman White Mans Magic Master Premium Member Dirty Wheel Club

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    Did they perhaps omit a decimal point? You'd certainly hope so, or perhaps they didn't convert from Japanese Yen first - that comes to a more sensible amount
     
  18. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    FCR's arrived. They are 33mm and from a 3TJ6 or 3TJ7. Took a bowl off and a bit fuzzy but not horrible.
    All of the o-rings and hoses will need to be replaced.
    3TJ6.jpg
     
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  19. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    Back to the Engine:
    When I removed my baffle plate, one of the screws was hell to get out. Going through the usual motions I hit it with the trusty butane torch until something smelt like burning rubber. Oops, on the other side was a bonded rubber gasket. Made a new one out of some sheet Viton and used the same low head cap screws that I mentioned before. With Loctite of course. Now you might be thinking, 'why not use some NBR'? Well that would be fine except I don't trust anyone to sell me the good stuff on an eBay purchase.
    BafflePlate_01_small.jpg BafflePlate_02_small.jpg
    I am doing a few mods to the gearbox and after that cases should be going together.
     
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  20. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    Been making a press, which is now close to being finished. Waiting for some hose barbs to arrive. I need them because I am inverting the jack. Then I can finish the gearbox stuff and put the cases together. I also picked up a Fizzer gearbox so I will make some seal rings and keep some bearings for them in stock.
    Press_01.jpg
     
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