1989 rebuild update

[oldman]

Thanks Calum, ordered 240 jet, did put 225 in, will do before fitting to bike, trying to build enthusiasm to go in cold garage!

[declan]

@oldman well my shed has a wire front so essentially I’m working outside always

[oldman]

@declan bummer! Exhausted myself turning the radiators on in my garage, phew!!!
On another note, ordered throttle cable from Yambits and fitted, doesn't fit at all well, difficult to get the slack out of the cable and definitely not right at oil pump. Shaft of cable that sits in housing far too long, have to fit a spacer on cable end to keep in correct position to line up clip on inside and cable in nearly the right position. Have ordered same as my 88 bike now, are there many differences in cables over the years? Mikuni carb and correct age cable ordered, just doesnt fit?

[Calum]

@oldman In my experience with cables, always best to go genuine. I've had nothing but headaches with aftermarket Yamaha Cables.

[oldman]

Am starting to agree with you, checked cable that bike came with and that was the same. Explains why premix in tank, oil pump would not work with that cable as too much slack if located correctly in to oil pump housing cable inlet, ah well, progress I suppose. Time wasted though , annoying, brakes tomorrow.

[oldman]

Photo shows todays progress, other picture shows bright spacer needed to get cable length correct, not right so replacement ordered.
Decal on front cowl incorrect as well, wrong size, will get right one with sticker kit.

[oldman]

[finnerz89]

Genuine throttle cables all the way. I tried 3 or 4 aftermarket ones and none of them fitted right at the oil pump

[oldman]

Have ordered genuine replacement, bike going to a friend and don't want any issues with it , needs to be pukka

[oldman]

Started on the brakes, rebuilt front master cylinder and refinished rear master cylinder and caliper mount, calipers next and genuine throttle cable if that arrives tomorrow

[oldman]

Rebuilt/refinished front master cylinder, genuine throttle cable arrived as well, joy!

[Calum]

Looking good.

[oldman]

Genuine cable operates carb and oil pump perfectly but stem that extends in to oil pump housing still too long to fit securing circlip? Definitely ordered correct year from Fowlers? Pattern part from same supplier I used for the red 88 yet to arrive but that was correct length to for circlip?
Stripped rear caliper and really grotty, paint removed (not hard, flaking off mostly) and cleaned, in ultrasonic cleaner prior to refinishing and reassembly. Pitting on piston but have new one anyway.
ANY comments about cable welcome?

[oldman]

Here's a pic of caliper before work. Nice!

[declan]

@oldman have you tried adjusting the cable in the junction box housing

[oldman]

It's not the cable, it's the outer metal end that protrudes throughout the cable entry of oil pump. There is a recess in the end of this for a circlip to prevent cable being pulled out of the oil pump housing. On my 88 bike the length was perfect, meaning you placed the metal shaft through the housing and the circlip secured cable outer tight to the housing. The Yambits cable just did not work, did not pull oil pump pulley unless outer sheath pulled out of oil pump housing 8 to 10mm, also difficult to take slack out of cable at throttle end. Hopefully pattern part I used previously will be here tomorrow to compare, will post some pics when I go back I'm garage.

[declan]

@oldman I did have this exact problem I had to make an adjuster using a clutch cable adjuster

[oldman]

Here is the caliper straight out of the ultrasonic cleaner ready for finishing, need a spray booth!

[oldman]

Cable adjuster wouldn't work, cable length is fine, length of metal insert to oil pump housing too long,

[Calum]

@oldman There is supposed to be a rubber o ring that goes on that metal insert FYI