Project The Yamaha R4 (Glacially Slow Project)

Oh no, not this old chestnut!
Talk about life getting in the way. Here is a TV stand I made coz I needed one to put the TV on to watch bike racing. It came from a tree that was cut down on the land about 8 years ago. No, you cannot buy dressed timber where I live. I had to build a router sled to mill it flat, or whatever wood people call that process.

Anyway, enough of that. I am putting the engine in the chassis and the plan is to start it. I even bought spark plugs today. They cost AUD4.34 each, ouch. Have to convert the carbs to non-restricted spec and give them a bit of an overhaul. Here is one of the green bowls after 3-Bond and a toothbrush. Luckily I know someone who has FCR seal kits.

 

But I don't like choppers.

 

Yamaha Spies:
From p34 of the race kit manual, set ICML at 102. Hey, that's how I do it.

 

There I was wiring the instrument cluster, only to discover the earth circuit is dead.
Took it apart multiple times looking for a dry joint/corrosion but no luck yet. Where is the magic wand when you need it.

 

Oh good God. I am such a moron. I had my wiring for the instrument cluster connector reversed. I bought another one for no reason.

 

"It's Alive!"
Connected the GPS sender and "calibrated" it, which means push a button until you get 60 kph showing. Next trick will be to take it for a drive in the car and see if it works. I'll reposition the tacho needle once the ignition module is connected.


Update:
I took it for a drive and it works.

 

... and stuck the engine in

 

It is texture black powder coat.

 

Airbox
Velocity stacks arrived. I accidentally bought two. First task will be to design and print the baseplate with the velocity stacks as part of it.

 

Clutch Lever Assy:
Mine had a broken lever and was too wide to fit the standard switch on the narrower R1 clipons. So I bought a Chinese copy.


Removed the switch and cut off the lug. The bush is loose in the lever and has a relief on the outside, dumb. The screw is made of chromed Chinesium. Fortunately I have the OEM screw from the old lever assy. I just have to shorten it a little and have it hardchromed next time I send off stuff for plating. Lastly, need to make a new bush that is an interference fit in the lever, and finish off with a Fuji nut.

 

Switch Nonsense:
I was trying to restore my old faded OEM switches. I gave up. Bought these plastic Chinese junk things.

They don't even tighten on the bar. Oh well, try again. This time I bought what looks like XL185 copies. Not only are bodies made of metal, but they even tighten on the handlebar. Hope springs eternal.

 

Sidestand:
My sidestand assembly used to look like this.

First, I cut (pink line) the section of plate steel that supported the switch off. The mount was powder coated when the frame was done.


I got a new bolt and fitted a grease nipple then had it nickel plated with some other bits.

Oops, looks like the smaller spring is not attached. Oh well, as it turns out the bike leans over too much, so I have to lengthen the sidestand anyway. Once I am finally happy with it, it will get powder coated when I send some Honda bits off.

 

Speaking of projects that take a while, Project Binky has an update.

 

I don't think there is anything "should have just used ..." about the entire project, and that to me is the appeal. Nik really wanted an updated version of the original cluster, so that is what they made. I'm sure Richard was pulling his hair out, but it's Nik's baby.