1972 Yamaha DS7 updates

[Redbird]

Not sure what forum this should fall into, but since it's pretty much one big mod project, here seemed as good a place as any :)

Well after getting her running at the Techday, this was todays tinker...

I'm waiting on a battery to charge, so no electrical work this time. I wanted to do something though, so I got the new tank fitted, and installed the clubman bars (thanks Juice:)).

http://i291.photobucket.com/albums/ll297/vialfmly/0224091235.jpg

http://i291.photobucket.com/albums/ll297/vialfmly/0224091234.jpg

I need to get the tank over to the Locksmith to have a key made for it, and I need to locate the correct fuel petcock. After that, it'll start getting prepped for paint.
I think both the tank and the bars completely transformed the look of the bike :D

[Rocky]

I bet 10 bucks that he has been rubbing on her since he got her back home last saturday. Looking good redbird, i can't wait to see more progress.

[Save-the-Manatee]

I love the look with the clubman bars! Keep up the good work.

[Klantz]

cafe racer? I'm thinkin so... it's about time to throw a kit on that thing...

[ONE LOVE]

What is that? 350?

[I_FLY_LOW]

How much different is this, to a 77' rd400?
There's one for sale...
Maybe an electrical upgrade, for yours, if need be?

[Redbird]

What is that? 350?

It's a 250.


How much different is this, to a 77' rd400?
There's one for sale...
Maybe an electrical upgrade, for yours, if need be?

Fundamentally, not much different. The 400 is (obviously) bigger, and probably has disc brakes. But 90% of the parts interchange.
Where's this one for sale? How much?

[Redbird]

Well, jumping the brown and blue wires gave me power at the coil and lights! Headlight works too! On/off switch and high/low beam. Taillight powers up, but no brake lights from either switch... need to do some more tracing :)
I need to get it warmed up enough to idle again to test the alternator for proper output. I may have to hook it up to the Stepside for that since the old battery I had lying around doesn't seem to want to hold much of a charge. I kinda expected as much, it's been sitting for almost a year.
Here's a few fresh pics...
LIGHTS!!!!
http://i291.photobucket.com/albums/ll297/vialfmly/0226091713a.jpg

http://i291.photobucket.com/albums/ll297/vialfmly/0226091713.jpg

No, I wasn't making vroom vroom noises...
http://i291.photobucket.com/albums/ll297/vialfmly/0226091734.jpg
...everyone knows 2strokes go Wingdingdingdingding LOL:D:D:D

[Zutopong]

:poop:

[Redbird]

UPDATE...
1) She has brake lights... It seems that they were operational the whole time, but the rear is misadjusted and the front isn't hooked to the lever (it's a weird setup).
2) Amazingly, the corroded/rusted mess of a regulator/rectifier actually WORKS! I got her running and hit the output wire with the testlight and got power. I verified proper operation by plugging it back into the harness and unhooking the jumper cables/battery... and she stayed running.
3) I also determined that it has no choke (I thought it was odd there was only a lever on one carb). It's actually a "prime" lever, and it works too.

The "bad" news is, I still don't have turn signals or a horn. I suspect the bar controls but still need to trace/jump some wires to narrow it down.

I'll be playing with her more on Wednesday ;)

[Bruce]

If Walt was available it would be all ready for an Around the world tour by now

[Redbird]

Hey hey hey, don't be ugly. I'm gettin there! :D

I've got vacation coming up in April. I plan/hope on having her ridable by the end of that week. ;)

[Bruce]

I was born ugly, some things I just can't change

[I_FLY_LOW]

cool deal, Chris! Keep er' up... you'll get it all figured out!

[Redbird]

UPDATE...

Bad News: Still no turnsignals. I found a wire terminal broken off the switch. I tried to solder it back on, but no luck. It's going to need to be replaced.

Good News: Horn works... sorta. The circuit works, but the horn itself is frozen. A new horn is in order.

Better News: I got the key made for the fuel tank. It only took $10 and ten minutes.
Now I can get it cleaned up and ready for painting.
http://i291.photobucket.com/albums/ll297/vialfmly/DS7/0311091826.jpg

"MacGyver is my Bitch" News: I got the ignition switch working!!
I pulled the headlight bucket off to get better access to the wiring (it had to come off to get painted anyway). While I still had wrenches in hand, I decided to remove the broken switch to get it out of the way. Well after getting the switch off I noticed there were two screws in the bottom holding the assembly together. I felt adventurous, so I took them out... the whole switch seperated. After surveying the circuits contact points, I determined that the "hot" going into the switch was corroded to the point of almost nonexistance. Which is why power was going in, but not out. Sooo, I planted a piece of solder on the top of what was left of the contact and filed it down to the height of the others.
http://i291.photobucket.com/albums/ll297/vialfmly/DS7/0311091610.jpg
After cleaning up the rest of the contacts I reassembled the switch and tried it out. It worked... but not well. It would flicker, and you had to play with the key to find the sweet spot. So I took it apart again. I then determined that it was missing a spring that holds pressure on the sliding contact. Sooo, one sacrificed "clicky-top" ink pen later, and that problem was solved.
http://i291.photobucket.com/albums/ll297/vialfmly/DS7/0311091631.jpg
After re-reassembling the switch... the darn thing works like a charm!

Now don't get me wrong, I don't plan to put full faith in this "fix". I'm still trying to locate a "correct" ignition switch (or I'll just "adapt" one and mount it on the frame or something) for permanent usage. But atleast now I don't have to keep moving a jumper wire around when I want different circuits to work :D

[Bruce]

It is looking better, maybe you can help me make my KLR pretty

[Team Redneck]

UPDATE...

Bad News: Still no turnsignals. I found a wire terminal broken off the switch. I tried to solder it back on, but no luck. It's going to need to be replaced.

Good News: Horn works... sorta. The circuit works, but the horn itself is frozen. A new horn is in order.

Better News: I got the key made for the fuel tank. It only took $10 and ten minutes.
Now I can get it cleaned up and ready for painting.
http://i291.photobucket.com/albums/ll297/vialfmly/DS7/0311091826.jpg

"MacGyver is my Bitch" News: I got the ignition switch working!!
I pulled the headlight bucket off to get better access to the wiring (it had to come off to get painted anyway). While I still had wrenches in hand, I decided to remove the broken switch to get it out of the way. Well after getting the switch off I noticed there were two screws in the bottom holding the assembly together. I felt adventurous, so I took them out... the whole switch seperated. After surveying the circuits contact points, I determined that the "hot" going into the switch was corroded to the point of almost nonexistance. Which is why power was going in, but not out. Sooo, I planted a piece of solder on the top of what was left of the contact and filed it down to the height of the others.
http://i291.photobucket.com/albums/ll297/vialfmly/DS7/0311091610.jpg
After cleaning up the rest of the contacts I reassembled the switch and tried it out. It worked... but not well. It would flicker, and you had to play with the key to find the sweet spot. So I took it apart again. I then determined that it was missing a spring that holds pressure on the sliding contact. Sooo, one sacrificed "clicky-top" ink pen later, and that problem was solved.
http://i291.photobucket.com/albums/ll297/vialfmly/DS7/0311091631.jpg
After re-reassembling the switch... the darn thing works like a charm!

Now don't get me wrong, I don't plan to put full faith in this "fix". I'm still trying to locate a "correct" ignition switch (or I'll just "adapt" one and mount it on the frame or something) for permanent usage. But atleast now I don't have to keep moving a jumper wire around when I want different circuits to work :D


Good freeking show RB, I might put a little higher quaility spring in the switch, but I would trust it!!!

It aint like ya gonna gonna be off in the wilds of Idaho on it.

[BradyM]

UPDATE...

"MacGyver is my Bitch" News: I got the ignition switch working!!
I pulled the headlight bucket off to get better access to the wiring (it had to come off to get painted anyway). While I still had wrenches in hand, I decided to remove the broken switch to get it out of the way. Well after getting the switch off I noticed there were two screws in the bottom holding the assembly together. I felt adventurous, so I took them out... the whole switch seperated. After surveying the circuits contact points, I determined that the "hot" going into the switch was corroded to the point of almost nonexistance. Which is why power was going in, but not out. Sooo, I planted a piece of solder on the top of what was left of the contact and filed it down to the height of the others.
http://i291.photobucket.com/albums/ll297/vialfmly/DS7/0311091610.jpg
After cleaning up the rest of the contacts I reassembled the switch and tried it out. It worked... but not well. It would flicker, and you had to play with the key to find the sweet spot. So I took it apart again. I then determined that it was missing a spring that holds pressure on the sliding contact. Sooo, one sacrificed "clicky-top" ink pen later, and that problem was solved.
http://i291.photobucket.com/albums/ll297/vialfmly/DS7/0311091631.jpg
After re-reassembling the switch... the darn thing works like a charm!


:respect: Nice.


You've got me wanting to find an old bike now, and I don't even have time to get my current bike fixed up how I want.

BTW: Don't know if the "MacGyver is my Bitch" quote is yours or not (I've never heard it, but I'm new), but that is some funny stuff right there!!!

[Redbird]

Walt, the only reason the fix makes me nervous is if that dot of solder pops off, Everything instantly shuts down. But it's cool for now. The bike won't be going out the 'hood for a while. Atleast not until I get it all sorted out. And who knows, if the switch proves itself, it may stay :)

Brady, I guess you could say it's mine. When my son got home from school, he saw me reassembling the switch and asked "Whatchya doin'?". I pulled it out of thin air and replied "Making MacGyver my Bitch". Of course his response was "Who's MacGyver?"
Kids these days :rolleyes:

Oh, and a small Update... New tires were ordered today. Chaparral Motorsports, $100 shipped, for the pair.

[Redbird]

Update...

I cleaned up the eBay motor in anticipation of putting it in the bike soon. The plan is to run this engine while I tear down and rebuild the original engine.
This was what I bought...
http://i291.photobucket.com/albums/ll297/vialfmly/DS7/94dd_1.jpg
This was after some clearcoat stripper and a pressure wash...
http://i291.photobucket.com/albums/ll297/vialfmly/DS7/0321091453.jpg
And this is after a few hours of painting and sanding/polishing accents...
http://i291.photobucket.com/albums/ll297/vialfmly/DS7/0321091622.jpg
http://i291.photobucket.com/albums/ll297/vialfmly/DS7/0321091622a.jpg
(the gold heads are kind of an "homage" to the old DG Performance heads)

After that I jumped on the electronics again.
I found a NOS switchgear on eBay for $20. It's originally for a '74-'76 Yamaha DT125, but it has all the correct functions. The only difference is it's black instead of silver. It wasn't hard to wire up either. Most of the color coding was the same, and the others weren't hard to figure out. So now I have fully functioning switchgear! But that uncovered two more issues...
1) The flasher relay isn't working. It's stuck open, so the signal lights will come on, but not flash. I'm going to order a digital relay since I plan on putting LED turnsignals in it anyway.
2) There's a problem with the turnsignal indicator in the gauge. It's apparently backfeeding the circuit because when either side of the TS switch is used, both sides light up. I started a "process of elimination" and narrowed it to the indicator light. After unplugging it from the circuit, each side lights like it's supposed to. I'll have to pull the light from the gauge and see what the problem is.

That's about it for now. The tires are on the way, and should be here early next week. Once they're in I'm going to pull the wheels and get them prepped/painted, and go through the brakes and bearings.

[mattc]

You got that engine looking nice... but does it run?

I'm loving this project!

[Redbird]

It's "suppose" to run. But I haven't actually run it yet. We'll see in about two weeks... maybe sooner.

Oh, and the new horn is in and functioning properly :)

[Team Redneck]

Looking Good RB!!!

Ya gonna ride it on the original engine before ya pull it out aint ya??

Sounds like a ground problem in you TS indicators. make sure both sides have a good ground.

Looks like I am going to work over for a couple of weeks. So it will still be a month or so before I can come out to play. Make hay while the sun shines I guess.

See yall then!!

[Juice]

Freaking sweet Redbird!!!!!!!!!!!!!!!!

[Redbird]

Woohoo! Tires just arrived!

I guess I know what I'll be doing this rainy Saturday :D

[Redbird]

Update...

Allrighty! When I ordered the tires I was a little nervous because it calls for a 90/90 on the front, and I had to go with a 100/90. Mainly because none of the manufacturers made tires that were priced reasonably AND in the sizes I wanted. I took a bunch of measurements and decided to chance the 100 on the front.
Well, the tire clears the forks with no problem... but won't fit in the fender. Eh, oh well. I was on the fence about keeping the front fender on anyway, this just made the decision for me.
After getting the front wheel off I noticed another problem right away.
The friction material is supposed to stay on the shoes... right?
http://i291.photobucket.com/albums/ll297/vialfmly/DS7/0404091737.jpg
I tried using superglue, but that didn't last long.
(of course I'm kidding :D)
I used up some elbow grease and did some light sanding and polishing (Mothers Powerball to the rescue!) on the hubs, and I painted the spokes and outer hub area.
Befores...
http://i291.photobucket.com/albums/ll297/vialfmly/DS7/0404091746.jpg
http://i291.photobucket.com/albums/ll297/vialfmly/DS7/0404091815.jpg
Afters...
http://i291.photobucket.com/albums/ll297/vialfmly/DS7/0404091854.jpg
http://i291.photobucket.com/albums/ll297/vialfmly/DS7/0406091718.jpg

I also mounted both new tires... by hand. (boy was that a PITA! I wish I knew somebody with a tire machine:)) I did the sanding on the rear hubs, but haven't hit them with the polish yet. I also need to paint the rear spokes/hub. That's where I'll start tomorrow.

Side note: All the bearings/bushings in both wheels and brake assemblies are in perfect shape. No slack and smooth as glass. I just need to get the brake shoes to reassemble everything.

[Juice]

Progress, looking good RB!!!!!!!!

[Bruce]

I have to say I admire your work and dedication to this job, and it looks great also

[mattc]

Looking good! What tires did you go with?

[Redbird]

Thanks Bruce, I appreciate it.

Matt, Bridgestone Spitfires. 100/90-18 and 110/90-18. Chaparral had them for $110 shipped.

[Redbird]

Well DAMN!!

Looks like 3-7 working days to get the brake shoes in.
Not looking good for me taking it down the street this week :(

[scootertrash]

Pictures of the whole bike?

[Redbird]

This was from the last Tech Day...
http://juicebox.smugmug.com/photos/478076222_q2eg3-L.jpg
That's probably the last time it was all in one piece.

[Redbird]

Update...

Since I have to wait on brakes, I kinda slacked off today.
(that, and the Stepside had to go to the muffler shop to fix a broken hanger and weld a crack in the muffler)

The wheels are done. Mounted, balanced, painted, polished, and waiting on brakes.
http://i291.photobucket.com/albums/ll297/vialfmly/DS7/0408091541.jpg

I messed with the electricals some today also. I got the proper bullet connectors to connect the headlight wiring, and I made the pigtail to properly connect the horn.
I'm thinking I might mount the wheels back on the bike, so I can move it to where I can swap engines. Or maybe I'll find something else to mess with...

[Redbird]

uuuuuuuuuuupDATE!!

Well I accomplished my goal for the week... I took her down the street!
This is me leaving...
http://i291.photobucket.com/albums/ll297/vialfmly/DS7/0410091338.jpg
And this is me coming back...
http://i291.photobucket.com/albums/ll297/vialfmly/DS7/0410091351.jpg
lol :D
I put the wheels back on, hooked her up to the truck battery, and got her warmed up.
Once warmed up I topped off the float bowls, and with no front brakes, sketchy rear brakes, and a frozen clutch pack... I got a good rolling start down the driveway... hit the street and kicked it into 1st gear... and it chugged and died. *crap*
I pushed it back up the driveway and jumped her off the truck again. Second attempt... pretty much same result... BUT, the clutch let go!! Woohoo!!
Back up the driveway for another jump. Now that I have clutch control, I'm thinking I could give her some gas and ease the clutch out. Let's try that! Third attempt... GOLDEN!
She bucked a little bit, but rolled on out through 1st gear. Clicked her up into 2nd gear... she didn't like that too much (carbs are still kinda wonky), and I heard that little voice say "no brakes dumbass". So back into 1st she went. I made it to the end of the block... made the turn around... and tried easing the throttle back open while feathering out the clutch... and she stalled... oh well... start pushing home.
I was hoping to get a little more out of her, but hey, she has been sitting dormant for quite a while... baby steps... baby steps :D
Here she is resting from her little trip.
http://i291.photobucket.com/albums/ll297/vialfmly/DS7/0410091515a.jpg
Next time we go all the way around the block... right girl ;)

[Redbird]

Update.

Well the goal was, I wanted her to go down the street under her own power.
She's done that... TWICE!




The new goal is: I want her to COME BACK under her own power!!!


I bought the new battery today, and she'll start AND idle by the second kick ;)
I filled the float bowls again and took her down the street. I got to the corner, made the turn around, and pluhhh... she died. But having the fresh battery helped me determine that she's running out of fuel by the time I get that far.
So I installed the petcock in the tank, and put the tank on the bike, and found out that the rear mount for the tank has to be changed.
It sits low in the rear and that puts the petcock resting on the engine. Not good.
Well, looks like I need to fab up a rear mount this weekend :D

[mattc]

Progress... hell yea!

[Redbird]

Update...

New brake shoes are installed. Fuel tank has been mocked up for bracket fabrication. The mock up has the tank temporarily mounted, so I put enough premix in it to make another test run... she made it down the block... AND BACK!!!
She's still running real wonky. She doesn't want to rev up from the lower RPM's, but once in the the upper RPM range, she seems to rev fine.
I need to get a fresh set of sparkplugs, and I need to pull the baffles out of the exhaust to see if it's clogged up.

Here's a few pics...
Fresh Fronts.
http://i291.photobucket.com/albums/ll297/vialfmly/DS7/0419091149.jpg
Fresh Rears.
http://i291.photobucket.com/albums/ll297/vialfmly/DS7/0419091116.jpg
And check this out... no need to remove the entire wheel assembly to change brakes!
http://i291.photobucket.com/albums/ll297/vialfmly/DS7/0419091117.jpg
Actually, you can then remove the wheel, and the sprocket assembly stays attached to the swingarm... with no need to re-adjust the chain.

[mattc]

Redbird, where's the vid of it firing up on the tech day? I didn't see it in this thread..

[Redbird]

I don't think I posted it in here. It was in the Techday thread.

But here it is anyway...
(edit: odd... the embed isn't working)
http://www.youtube.com/watch?v=4DTTmqESsOk

And just a little bit of an update... I pulled the baffles out. One was real oily and generally gummy, but the other was nearly completely clogged with a dry substance. I think a mud dauber may have called it home for a while.
I took her down the street with out the baffles (man is she loud!) and she ran tons better.

[LAYNFRM]

I took her down the street with out the baffles (man is she loud!) and she ran tons better.

that's how it's SUPPOSED to be! 2 strokes FTW!

[ONE LOVE]

subscribed

[Redbird]

Update...

While I'm waiting on parts, I decided to fabricate/install my LED mod to the taillight. Here's what I did...
I took a 4' round LED light originally for a trailer. These are the same LED lights you'll see on the back of tractor/trailers. The one I got was a low profile design, which required much less 'trimming' to get it into the stock housing. I then went about removing everything I didn't need... like the cover lens, and just enough perimeter material for it to slide all the way into the stock taillight lens. (I used my bech grinder for this) I also needed to clearance the fixture in three places for the screw channels. (I used my bench grinder for this also. A rat tail file makes a cleaner look, but I couldn't find mine)
Afterwards you end up with something like this...
http://i291.photobucket.com/albums/ll297/vialfmly/DS7/0501092015_1.jpg

http://i291.photobucket.com/albums/ll297/vialfmly/DS7/0501092016_1.jpg

Now as you can see in the pics... what I did for the pigtail connection, was I took an old 1157 bulb and broke the glass off of it. I then soldered wires to the filament leads, and shrink tubed and taped the connections. This allows the LED fixture to be attached just like an 1157 bulb, and can be removed just as easily.
This is the end result. It's 10 LED's, 9 around the perimeter and 1 in the center. It's all contained inside the stock taillight housing, and can be converted back to stock in about sixty seconds.
Running light...
http://i291.photobucket.com/albums/ll297/vialfmly/DS7/0501092021a_1.jpg

Brake light...
http://i291.photobucket.com/albums/ll297/vialfmly/DS7/0501092021_1.jpg

MUCH brighter than the stock 1157 bulb :D

[Klantz]

That's a really nice mod. Well done!

[Redbird]

Update...

New seat is in :D
http://i291.photobucket.com/albums/ll297/vialfmly/DS7/0512091806.jpg

I'm still waiting on fuel tank mounts. I need the mounts to properly locate and attach the tank, and I can't mount the seat until the tank is mounted. But... this weekend I'll be removing the rear fender and starting to mock-up a new taillight mount and inner fender panel.

EDIT: I forgot to mention... last Sunday we loaded the DS7 and the pocketbike into the truck and brought them over the Zephyr Stadium parking lot. The boys ran around on the pocketbike while I did "reliability trials" on the DS7. I unloaded her and tooled around for for a full TWO MINUTES... and she died.

It would appear she likes to run with the fuel petcock in the ON position Doh

Once she was getting fuel she ran around for well over 30 minutes with no trouble at all. I was even doing low speed circles and dragging the pegs. She handles fairly well, even with the shitty forks:D
Check out the skinny "chicken strips"...
http://i291.photobucket.com/albums/ll297/vialfmly/DS7/0503091602a.jpg

[Redbird]

Update...

Still waiting on the fork seals and fuel tank grommets, but I got a little bit done today.
I picked up a set of side panels for a '75 RD350 off eBay. They've got a smoother shape to them than the originals. I got the decals stripped off of them and the fuel tank. And I hit them with a coat of paint to keep the rust at bay. Now I need to pick up some Bondo to take care of the dings.
Here's a 'before' pic of the side panels:
http://i291.photobucket.com/albums/ll297/vialfmly/DS7/da13_1.jpg
and 'after':
http://i291.photobucket.com/albums/ll297/vialfmly/DS7/0522091710.jpg

I also got the rear fender/grab bar/taillight removed. I plan on fabbing an inner fender to keep dirt and other road stuff away from the carbs.
Here's the 'new(for now)' look...
http://i291.photobucket.com/albums/ll297/vialfmly/DS7/0522091851.jpg

[Redbird]

Update:

Fuel tank is mounted! Drug the bike over to a friends racecar shop and fabbed up some brackets. Basically, it's a piece of flat stock made to look pretty, drilled and tapped, and welded to the frame.
http://i291.photobucket.com/albums/ll297/vialfmly/DS7/0603091630.jpg
http://i291.photobucket.com/albums/ll297/vialfmly/DS7/0603091636.jpg

I also got the R6 rearsets mounted up. Fabbed up a couple of tabs, welded them to the frame and voila'...
http://i291.photobucket.com/albums/ll297/vialfmly/DS7/0603091618.jpg
http://i291.photobucket.com/albums/ll297/vialfmly/DS7/0603091614.jpg

I still have to dress the welds and hit them with some paint. Now I need to get the linkages worked out so they'll operate properly;)

Next Wednesday I'll be back over at the racecar shop to fab some more brackets to mount the new Cafe Seat:D

[Juice]

Any day with progress is a good day. Looking good RB!

[Klantz]

That thing is lookin sweet! We'll have to start a new section of the forum for the cafe racers...

[allanj255]

Nice looking bike:1stplace:

[Redbird]

Update:

Yesterday I rebuilt the "new" forks and installed them. I had no idea how 'sticky' the old ones were. But the new ones ride smoooooth:)
I also installed new Uni pod filters, a working tach cable, and changed th oil.
No pics, because there really wasn't much to see. But Wednesday I'll be back over at the racecar shop to fabricate the mounts for the cafe seat. Pics will follow;)

[Redbird]

Update:

Cafe seat is mounted. Made a couple of "bridges" across the frame, drilled and tapped, added some rubber bushings, and presto!
http://i291.photobucket.com/albums/ll297/vialfmly/DS7/0610091426.jpg
http://i291.photobucket.com/albums/ll297/vialfmly/DS7/0610091701.jpg

She's getting close ;) :)

[Dusty]

Thats hot!!!!!!!!!!!!

[Juice]

Chris, let me know if you would like the full Res. images.


http://juicebox.smugmug.com/photos/576283159_pK9eL-M.jpg


http://juicebox.smugmug.com/photos/576284136_aS7ex-M.jpg


http://juicebox.smugmug.com/photos/576287931_2DBHN-M.jpg


http://juicebox.smugmug.com/photos/576288600_ufHUe-M.jpg


http://juicebox.smugmug.com/photos/576295799_kkP56-M.jpg


http://juicebox.smugmug.com/photos/576298189_tUiCz-M.jpg


http://juicebox.smugmug.com/photos/576300128_egSda-M.jpg

[Redbird]

Juice, HELL Yea! Thanks a bunch :D
You're one helluva photographer to make me look that good! :)

Update.

The Good News is... All my linkages that I just fabbed up worked like a charm. (I'll post pics of them shortly) Nothing loosened up or fell off the bike at any time while I was on course. And she actually handles pretty good for an old girl.
The Bad News is... at the end of my second session... she siezed up pretty hard. Luckily I had just exited the track. I got her home and tried messing with her a little bit. She kicks over now (wouldn't do it at NPR), and tries/wants to run, but nothing more.

Oh well... I was had such a blast throwing her around NPR, I think it was worth it. I still have the spare engine anyway, so that'll go in next. Then I'll rebuild the original engine.

[Redbird]

As promised, here's the pics of my adapted rearsets. The rearsets are from an '05 R6. (many thanks to Docadams and Pablo) I fabbed up some tabs and had them welded to the frame. I then used spherical rod ends and some allthread to make the linkages.
http://i291.photobucket.com/albums/ll297/vialfmly/DS7/0628090814.jpg
http://i291.photobucket.com/albums/ll297/vialfmly/DS7/0628090815.jpg
http://i291.photobucket.com/albums/ll297/vialfmly/DS7/0624091819.jpg

[Redbird]

Update.

Well I finally got off my ass and pulled the broken bullet.
Left side cylinder looks great! Right side cylinder is toast...
http://i291.photobucket.com/albums/ll297/vialfmly/0715091424.jpg
This is all the crud I scraped off the frame before I pushed it outside...
http://i291.photobucket.com/albums/ll297/vialfmly/0715091423.jpg

The frame is currently soaking up some degreaser, and will get "a douche and a powder" shortly :D

P.S. PB Blaster is my new best friend ;)

[allanj255]

Rear sets look good, nice job :respect:

[Bruce]

I wish I had half the energy you put in that bike to put in mine. I don't think I will ever fix it, but I can admire your work

[Redbird]

Thanks for the compliments guys :)

Well, here's the squeeeeeky clean frame.
http://i291.photobucket.com/albums/ll297/vialfmly/DS7/0715091511.jpg
I later touched it up with a little bit of rattlecan black too.

New bullet is in. and it RUNS!!! :D
http://i291.photobucket.com/albums/ll297/vialfmly/DS7/0715091810.jpg
It runs atleast as good as the other one... before it broke:) I'm not going to run it too much until I can get it jetted properly (don't wanna seize this one too;))
While I had it all apart I was also able to get the pipes cleaned up much better, and the kick/center stands are crud free now too.

More to come later :D

[Redbird]

Update.

I took it back over to the racecar shop today to add another bracket to the frame. I had previously removed the (broken) stock friction plate style steering damper in anticipation of installing something newer. I picked up a GSXR damper from Jeepers on RM. After doing a little test fitting, I realized two things... a) the existing bolt hole from the old damper is the same size as the new damper (no need to fab a bracket for that side) and b) the "ugly" side of the damper was going to be facing out. So I dropped it off with Rusty Jr. who took it apart and "flipped" the slider rod. After a quick session with a cutoff wheel, drill, and bench grinder, I had the only bracket needed for the install. A few zaps with the welder later and...
http://i291.photobucket.com/albums/ll297/vialfmly/0812091058.jpg
(a better looking bolt and some touch-up paint came later)

Big THANKS to Jeepers and Rusty Jr :respect:

Next on the agenda is proper carb jetting... stay tuned :D

[I_FLY_LOW]

Wow! it turned out nicely!

[mattc]

Wow! it turned out nicely!

+1 for the bling! :1stplace:

[scootertrash]

Wow! That thing sure has come along way since I saw it at the Crawfish Boil, looks like fun.

[Redbird]

Wow! That thing sure has come along way since I saw it at the Crawfish Boil, looks like fun.

Thanks for the kudos guys. And yea, it has come a long way. Hard to believe it was only six months ago Walt brought her back to life. She's real close to being street ready.

Speaking of Walt... has anyone seen or heard from him lately?

[chuckklr04]

Needs a rear tank and saddlebags.rocket.ride

[Redbird]

Update.

Played a little with the headlight bucket today. After a quick trip to Radio Shack to try and find a new "Highbeam Indicator" light, I also picked up two LED lights in amber. Since I haven't been able to dtermine why exactly the common turn signal indicator is backfeeding, I had the idea to add signal indicators into the headlight bucket next to the Highbeam indicator.
This is what I ended up with...
http://i291.photobucket.com/albums/ll297/vialfmly/DS7/0815091928.jpg

I also fabbed up a taillight bracket. This started out as a 1/4" thick, 6" wide aluminum L-bracket. After several hours of measuring, test fitting, drilling, dremeling, hacking it up with a Porta-ban, grinding, some mild bending, and a little paint.
This is what I ended up with...
http://i291.photobucket.com/albums/ll297/vialfmly/DS7/0815091929.jpg
This is the bracket and taillight mounted...
(disregard the rough cut on the seat. it's not done yet)
http://i291.photobucket.com/albums/ll297/vialfmly/DS7/0815091943.jpg
http://i291.photobucket.com/albums/ll297/vialfmly/DS7/0815091944.jpg

Tomorrow is carb jetting day. Stay tuned :D

[mattc]

Looks very nice! I know that took quite a bit of work...

[LiteHeaded]

Very nice fab work. Looks like it was born there:respect:

[Redbird]

Thanks. The taillight bracket was probably a little bit overkill, but it's definitely not going to flop/bounce around while I'm riding :D

Update.

The carbs are close. Of all the jets I had aquired, the smallest was a 130. Stock is a 100. In case you're not familiar (I wasn't), that's about the diameter difference between pencil lead and the pencil itself. That's a BIG jump. The consensus is I'm going to need about 110-112's. We raised the needles up one notch, so it's now running kinda fat in the midrange and about right on top. But it doesn't really have the throttle response that it should.
I'll be ordering jets this week and doing more tuning ;)

[Redbird]

Update.

Oooooooo, Aaaaaaaahhhh...
http://i291.photobucket.com/albums/ll297/vialfmly/DS7/ds7tanks005.jpg
http://i291.photobucket.com/albums/ll297/vialfmly/DS7/ds7tanks003.jpg
http://i291.photobucket.com/albums/ll297/vialfmly/DS7/ds7tanks008.jpg
http://i291.photobucket.com/albums/ll297/vialfmly/DS7/ds7tanks007.jpg

All of the body panels are going to Ben next week for the Wrap.

I also did a bunch of wire re-routing and securing. Harness looks alot "cleaner" now. New LED flasher relay is in and working properly... awaiting turnsignals. "Engineered" the foot brakelight switch (adapted '05 R6 - '72 DS7), so now the brakelight works properly.

More to come ;)

[allanj255]

Looking good

[Klantz]

man that thing is gonna look awesome when it's all put back together!

[mattc]

Very good looking paint!

This thing is going to be wayyyy too nice!

[Juice]

To crash at the track!!!


This thing is going to be wayyyy too nice!

[Redbird]

To crash at the track!!!

Bite your Tongue!!!

It's not going to be a trackbike though. That was never the plan.
It'll probably make it out to NPR again, but only for exhibition passes and photo ops. Maybe some "period correct" shots with me in jeans, boots, old style leather jacket, turtle shell helmet, and goggles :D

[Redbird]

Update.

While I'm waiting on the wrap, I've been doing some cleaning/painting/polishing/etc.
This was todays project...

Before.
(not really a fair pic though. I did a bunch of cleaning on it before I took the pic)
http://i291.photobucket.com/albums/ll297/vialfmly/DS7/0909091734a.jpg

After.
http://i291.photobucket.com/albums/ll297/vialfmly/DS7/0909091734.jpg

Much mo' better :D

I was able to scratch about four things off the "To-Do" list, but lost enough light to make pics difficult. I'll shoot a few tomorrow;)

EDIT: Click HERE (http://www.dualsportridersoflouisiana.com/forums/showpost.php?p=70641&postcount=33) for a better "Before" shot of the shocks ;)

[Bruce]

When you want to start on my KLR

[Redbird]

What's wrong with your KLR? I thought they got you fixed up at the techday.

[Bruce]

It was fixed at tech day bit I have had a few problems with it since and have been depressed over it and have had an offer to fix it but haven't done anything with it . I hope I can get motivated to get it back together soon

[Redbird]

In the immortal words of Nike's ad agency... Just Do It! :D

[Redbird]

Update.

Still doing some cleaning/polishing/etc.
I got the triples painted, the handlebar risers cleaned up, the gauge buckets polished, replaced some rusty nuts/bolts, and cleaned up others.
http://i291.photobucket.com/albums/ll297/vialfmly/DS7/0912091605.jpg
I got the levers and perches polished up, and cleaned up the broken ends on the levers (ground the ends round, smoothed them out with progressively finer sandpaper, and rubbed the whole essemblies with #0000 steel wool). I also worked some more on the steering damper. It's starting to get some shine to it :)
http://i291.photobucket.com/albums/ll297/vialfmly/DS7/0912091709.jpg

I should have the bodywork back early next week, so reassmbled pics should follow soon ;)


Oh, btw, does anyone have a "fix" to get the moisture out from the inside of the gauge lenses?

[mattc]

Again, as always, nice work. You're doing that little bike proud!

[Bruce]

I wish I had just a little of your motivation, GREAT Work

[Redbird]

And here she is. All cleaned and primped... waiting on her new "Sunday Best" outfit.

http://i291.photobucket.com/albums/ll297/vialfmly/DS7/0913091629.jpg

http://i291.photobucket.com/albums/ll297/vialfmly/DS7/0913091629b.jpg

The only two things I haven't crossed off the list were 'Jetting', which needs to wait for the tank. And 'Turn Signals', because I haven't decided what style I want to put on her yet.

[I_FLY_LOW]

Man that things looking better and better!

[Juice]

I concur!!!


Man that things looking better and better!

[Klantz]

lookin sweet man!

[Redbird]

Oooooooooo... I got emailed a pic of the vinyl for my wrap!


Not sure I'll be able to sleep tonight.

[I_FLY_LOW]

hmm...
I can't seem to see any of the pics you posted of it...

[Redbird]

odd, they show up fine for me.

[I_FLY_LOW]

:redx2:Not seeing a single pic of the new wrap...

[Redbird]

Oh, hahaha.

I haven't gotten the bodywork back yet. I went and saw the vinyl print today... it's going to look awesome!

[Redbird]

Ok guys... the bodywork is back on the bike... with the new wrap.

I've got good news and bad news...
The Good News is, she looks Awesome!!!
The Bad News is, is too dark for me to take pics.

But I will give you a teaser pic. This is one Rusty sent me while he was putting the wrap on...










http://i291.photobucket.com/albums/ll297/vialfmly/DS7/Photo0118.jpg

[Redbird]

Ok, here she is with her new clothes...
http://i291.photobucket.com/albums/ll297/vialfmly/DS7/splatrace060.jpg

http://i291.photobucket.com/albums/ll297/vialfmly/DS7/splatrace061.jpg

http://i291.photobucket.com/albums/ll297/vialfmly/DS7/splatrace062.jpg

http://i291.photobucket.com/albums/ll297/vialfmly/DS7/splatrace063.jpg

http://i291.photobucket.com/albums/ll297/vialfmly/DS7/splatrace064.jpg

In case you couldn't tell from the "teaser pic", she's wrapped in Carbon Fiber! The idea behind it was a Old School meets High Tech look. It really came out nice.
Here's a few shots of her from today at the Splat Race...
http://i291.photobucket.com/albums/ll297/vialfmly/Splat%20Race/splatrace017.jpg

http://i291.photobucket.com/albums/ll297/vialfmly/Splat%20Race/splatrace020.jpg

http://i291.photobucket.com/albums/ll297/vialfmly/Splat%20Race/splatrace026.jpg

http://i291.photobucket.com/albums/ll297/vialfmly/Splat%20Race/splatrace044.jpg

I know Stu got some shots of her too. I can't wait to see how they turned out :)

[thedrizel]

http://i291.photobucket.com/albums/ll297/vialfmly/Splat%20Race/splatrace017.jpg


This is BY FAR the best "accessory" on your bike! :D

[Redbird]

I agree. Too bad the wife would let me keep it on :(

[chuckklr04]

Sweet bike!

But where will you put the aux tank?

[chuckklr04]

I agree. Too bad the wife would let me keep it on :(

Only needs to be on for ten minutes...................

[Bruce]

If I had not seen this transformation a few steps at a time, I would never have believed this was the same bike. I admire your hard work on it very much.

[Klantz]

FREAKIN SWEET! That thing looks awesome!

[Juice]

She sure is pretty. Nice job Chris!!!!

[Redbird]

Thanks guys :D

Has anyone heard from Walt lately?

[Juice]

I called and sent him a pm about two weeks back. He must be out of country and off the grid.
Thanks guys :D

Has anyone heard from Walt lately?

[I_FLY_LOW]

I've seen postings from him on ADV recently...
he's around, somewhere with internet...

[Redbird]

What's his screen name on ADV?

[Juice]

Dwalt
What's his screen name on ADV?

[Team Redneck]

I'm here!!

Just been busy with life and stuff, you know......

Wanted to make the Campout, but I'm going to be on the water.

It's hard to belive that was the coughing, smoking hulk we CPR'ed to life way back when.

Good fuckin' job Red!!!

[Ozark12002]

hey red if you ever get the itch to work on another bike I have a 1979 honda cx 500 custom that I started on but just been in need of some help to finish ok alot of help LOL

[Redbird]

Walt, I couldn't have done it without your help. It quite literally "all started with you".
You still have that ride reserved for ya too ;)

Ozark, I'm going to ride this one around for a little while before I take on another project. But, this might be an interesting conversion...

http://farm3.static.flickr.com/2136/2452440424_c8eb529386.jpg

[Ozark12002]

Walt, I couldn't have done it without your help. It quite literally "all started with you".
You still have that ride reserved for ya too ;)

Ozark, I'm going to ride this one around for a little while before I take on another project. But, this might be an interesting conversion...

http://farm3.static.flickr.com/2136/2452440424_c8eb529386.jpg

I don't want to sell it I need help finishing it up I had it running about 6 months ago but have not touched it since ( need to save for parts lol ):nopity:

[Redbird]

Oh I know. I wasn't trying to buy it :)

[Zutopong]

Nice job!

[Redbird]

Here's a couple of more recent pics.
I snapped these after I installed the "YAMAHA" and "250" decals...
http://i291.photobucket.com/albums/ll297/vialfmly/DS7/ds7-busa012.jpg
This one shows off the Carbon Fiber wrap...
http://i291.photobucket.com/albums/ll297/vialfmly/DS7/ds7-busa012_crop2.jpg
A shot of "The Girls"...
http://i291.photobucket.com/albums/ll297/vialfmly/DS7/ds7-busa008.jpg

These are from Phil (I Fly Low). He shot them at the Hooters Block Party last Tuesday night...
http://i29.photobucket.com/albums/c260/chevyman962000/Hooters%20Bike%20Nite%20Denham%2010-6-09/IMG_62621024x768.jpg

http://i29.photobucket.com/albums/c260/chevyman962000/Hooters%20Bike%20Nite%20Denham%2010-6-09/IMG_63801024x768.jpg

http://i29.photobucket.com/albums/c260/chevyman962000/Hooters%20Bike%20Nite%20Denham%2010-6-09/IMG_63941024x768.jpg

[Zutopong]

Very impressive, that old girl cleaned up nicely. Excellent work my friend. Bravo!

[Save-the-Manatee]

I love anything vintage, nice work.

[Juice]

Looking good RB!

[Redbird]

Finally!!!
http://i291.photobucket.com/albums/ll297/vialfmly/Mobile%20Uploads/1114091345.jpg

http://i291.photobucket.com/albums/ll297/vialfmly/Mobile%20Uploads/1114091345a.jpg

Picked up a nice set of chambers for cheap from a guy on a 2stroke forum.
Arrived yesterday, cleaned/prepped/painted/installed today :D

I ran out of daylight so bike pics will follow tomorrow ;)

[allanj255]

Good looking bike.

[Redbird]

Pics...

http://i291.photobucket.com/albums/ll297/vialfmly/Mobile%20Uploads/1115091647.jpg

http://i291.photobucket.com/albums/ll297/vialfmly/Mobile%20Uploads/1115091648.jpg

I scuffed them and applied the High Heat Satin Black finish. But I think I'm going to pull them down and paint them something lighter. I'm thinking thye blend too much as is.

[Juice]

More importantly, how does it sound?

[Redbird]

Like sex... really angry, mean, gothic S&M sex. And I mean that in a good way :D

[Klantz]

I say stick with the black... who needs to see it when you can hear it!

[Redbird]

I FINALLY GOT IT!!!

The text is photo'chopped, but it has real numbers on it and a registration sticker and everything!!!

http://i291.photobucket.com/albums/ll297/vialfmly/Mobile%20Uploads/tag.jpg

Now I can ride it around wherever I want... LEGALLY!! :D :D :D

[Swampy]

Sweet... Mine has a plate on it to... But not a seat.. LOL..

We will get together and ride one day soon...

[bigtattoo79]

Sweet... Mine has a plate on it to... But not a seat.. LOL..

We will get together and ride one day soon...

Hey Now!

[Swampy]

LOL... That wasnt a jab... I dont have a valve cover gasket yet either...

Or blinkers or brake light... LOL...

[Redbird]

Update.

Headlight Upgrade...
I finally upgraded the headlight to one recommended to me from Parts-N-More. Very nice piece of equipment. The fit and finish is excellent, and basically bolted right up. It's a little bit deeper than the stocker, so it's a little snug on the backside. But nothing serious. The only mod necesary was drilling a hole in the shell to fit the Highbeam Indicator. I was also able to source the correct 35/35 H4 bulb from a local scooter shop for $10.

http://i291.photobucket.com/albums/ll297/vialfmly/DS7/1226091654.jpg

Legality Upgrade...
I finally got the License Plate mounted. I'll pick up a frame and some better looking bolts soon. But otherwise, this is it.

http://i291.photobucket.com/albums/ll297/vialfmly/DS7/1226091654a.jpg

I still have to add turnsignals, but since I haven't decided exactly what I want to do on that subject... and they won't significantly change the appearance... I'm going to call the bike Done!
(well, as much as any bike can be called "done" :D)

[Swampy]

Very nice.... I love it.... I just put the front blinkers on mine... I used some mini cat eye blinkers...

http://img.photobucket.com/albums/v122/swampboy/IMG_0421.jpg


Hard to see, because I had on some heat lamps in my garage ......

I drilled the mounting holes in the headlight ears...

[Redbird]

Fork brace upgrade...

I picked this up for $25 off ebay...
http://i291.photobucket.com/albums/ll297/vialfmly/DS7/Bv32SyEWkKGrHqUOKnIEvyFrzKsmBMGW818.jpg
"Yamaha Fork Brace Vintage AHRMA MotoX"

It started out about 1 1/2" too wide. I took and braced the inside where the tire would ride (to keep that measurement), and squeezed it together. I then reangled the mounting tabs to be verticle again, and match the distance between the forks. The end result is shaped more like a lightbulb than an upsidedown U. Drilled a few new bolt holes, trimmed off some excess material at the bottom, rubbed on it with some polish, and viola'...
http://i291.photobucket.com/albums/ll297/vialfmly/DS7/utf-8BSU1BRzAwNjAuanBn.jpg
http://i291.photobucket.com/albums/ll297/vialfmly/DS7/utf-8BSU1BRzAwNjEuanBn.jpg