Well it has been a while since I updated, but I have been plugging away at the project. I have been taking components off individually and bringing them inside all winter and cleaning them up and painting or zinc plating them as I go. I now have the engine out now and all that is left to strip from the frame is the front suspension and a few other little bits. I have decided to go with painting all of the components including the frame rather than powder coating. I have been impressed with the chassis paint I bought in the spray can and it has done a really good job, so i think I will save some cash and do the painting myself.
For this update, I am going to go through the cleaning and refurbishing of one of the key little components that make this two stroke street bike a little more civilized, the oil injection pump.
Above you can see the side cover, which I also redid as part of this task, the pump is housed under the front of that cover.
What this little pump does is take oil from a tank and inject the correct amount depending on throttle position into the carburetors to lubricate the engine. Before these pumps were created you had to premix the oil with the gas when you fill up which is a hassle and has the problem of starving the engine of oil at idle, so coasting down a hill could seize your engine! So, this component is really vital to prevent engine damage.
Yamaha never meat this pump to be user serviced, in the service manual that simple say to get another pump from your dealer if yours fails. Fortunately, these little pumps are near indestructible. The problem is oil leaks getting oil all over my nice clean engine. I found a few places that sell seal kits for about $35 that come with the 4 oil seals you need and new screws for the body and gaskets. So I carefully took the pump apart and I see why they aren't user serviceable, it is full of some very, very tiny parts. There are two gear retaining pins that are literally 2mm long and .75mm thick! I managed to get everything replaced and back together and turned the pump by hand and it works, it was like watch repair.
Below is everything back in place like I found it, I plan on getting new screws to replace those rusted 3 screws holding the pump cover on, but other than that it isa ready to go on the engine.
For this update, I am going to go through the cleaning and refurbishing of one of the key little components that make this two stroke street bike a little more civilized, the oil injection pump.
Above you can see the side cover, which I also redid as part of this task, the pump is housed under the front of that cover.
What this little pump does is take oil from a tank and inject the correct amount depending on throttle position into the carburetors to lubricate the engine. Before these pumps were created you had to premix the oil with the gas when you fill up which is a hassle and has the problem of starving the engine of oil at idle, so coasting down a hill could seize your engine! So, this component is really vital to prevent engine damage.
Yamaha never meat this pump to be user serviced, in the service manual that simple say to get another pump from your dealer if yours fails. Fortunately, these little pumps are near indestructible. The problem is oil leaks getting oil all over my nice clean engine. I found a few places that sell seal kits for about $35 that come with the 4 oil seals you need and new screws for the body and gaskets. So I carefully took the pump apart and I see why they aren't user serviceable, it is full of some very, very tiny parts. There are two gear retaining pins that are literally 2mm long and .75mm thick! I managed to get everything replaced and back together and turned the pump by hand and it works, it was like watch repair.
Above is the finished product out of the housing, all new seals in place and the shiny new screws all tightened and cleaned up. Below is the pump installed back in the cleaned up, repainted and polished engine cover.
Below is everything back in place like I found it, I plan on getting new screws to replace those rusted 3 screws holding the pump cover on, but other than that it isa ready to go on the engine.
Next up is the rear swing arm assembly and followed by that soon by the engine inspection. I have another bike in pieces right now in the garage, plus it has been super cold in Minnesota this winter which cuts down on my initiative to get out to the shop.
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