Other 1993 Yamaha WR500 Teardown/Overhaul
- Thread starter SRAD97750
- Start date
Well, we'll start out this updated with new part that came in the mail! A brand new RK 520X118 standard chain with clip type master link.
And! Threw the crank in and seated it against it's bearing. One really good look over to ensure everything is installed and in place.
Got my bolts organized clockwise from the top so I'm not fiddling with bolt lengths...
Test fit to ensure the shift star lines up with its recesses. 1st gear was the trick!
Applied grease to the bearings and journals for an easy installation. Slapped them case halves together!
Yes, I am liberal with the sealant. Not planning on pulling these cases again for some time.
Sealant I used is the yamabond 4 equivalent. "For rigid flanges, semi-hardening, permanent assembly, completely fuel and solvent resistant." It was even stringy like yamabond 4.
Squeezed out and cleaned up. Torqued the bolts to spec in the star pattern per the maintenance manual.
Everything spins freely and shifts through the gears smoothly.
More to come!
-BIG DAN
And! Threw the crank in and seated it against it's bearing. One really good look over to ensure everything is installed and in place.
Got my bolts organized clockwise from the top so I'm not fiddling with bolt lengths...
Test fit to ensure the shift star lines up with its recesses. 1st gear was the trick!
Applied grease to the bearings and journals for an easy installation. Slapped them case halves together!
Yes, I am liberal with the sealant. Not planning on pulling these cases again for some time.
Sealant I used is the yamabond 4 equivalent. "For rigid flanges, semi-hardening, permanent assembly, completely fuel and solvent resistant." It was even stringy like yamabond 4.
Squeezed out and cleaned up. Torqued the bolts to spec in the star pattern per the maintenance manual.
Everything spins freely and shifts through the gears smoothly.
More to come!
-BIG DAN
That is some daaamn good dirt bike porn !
I am not too proud to admit I was touching myself ever so slightly while viewing these pics.
I am not too proud to admit I was touching myself ever so slightly while viewing these pics.
Thanks!
I applied light grease to all mating surfaces in the transmission. Also, I will pre-lube the crank bearings, rod bearings, and piston rings at installation with 2T oil. As far as the rest is concerned, I will do a full flush of the transmission just prior to filling with the final oil. This flush will include inverting the engine, with excessive oil in the case, while rotating the transmission components.
Not a conventional method, but
I was not interested in compromising the case sealant application/integrity, with a light film of oil on everything...
-BIG DAN
Thanks!
I applied light grease to all mating surfaces in the transmission. Also, I will pre-lube the crank bearings, rod bearings, and piston rings at installation with 2T oil. As far as the rest is concerned, I will do a full flush of the transmission just prior to filling with the final oil. This flush will include inverting the engine, with excessive oil in the case, while rotating the transmission components.
Not a conventional method, but
I was not interested in compromising the case sealant application/integrity, with a light film of oil on everything...
-BIG DAN
Good idea, I never thought about doing it that way.
That is some daaamn good dirt bike porn !
I am not too proud to admit I was touching myself ever so slightly while viewing these pics.
Simma down, Simma down...we don't want you loosing your wad too soon before Dan gets done
Too late - I already took out two acoustic ceiling tiles from my wreck- room. I furk'n lurvs Biggy-D's build threads.Simma down, Simma down...we don't want you loosing your wad too soon before Dan gets done
OK. This have been on hold due to a mistake I made.
Apparently the RH crank seal is different than the LH. I managed to destroy both in the process and reorder the wrong seal 3 times... The illustrated parts catalogue (IPC) yamaha provided online is incorrectly labelled.
OH well. BK and I figured out the actual part number and I found one in stock at chaparral. Had them set it aside for me.
In the end, only a $50 mistake in a $2000+ overhaul. I can deal with that.
So saturday (tomorrow) I will be driving down to pick it up, and drop off some items for powdercoat.
The new LH crank seal also comes on saturday via USPS.
I will be paying/ordering the remaining aftermarket items required for this build TODAY. SO....
STAY TUNED... not alot to hold me back at this point. Just getting it together the right way the first time!
-BIG DAN
Apparently the RH crank seal is different than the LH. I managed to destroy both in the process and reorder the wrong seal 3 times... The illustrated parts catalogue (IPC) yamaha provided online is incorrectly labelled.
OH well. BK and I figured out the actual part number and I found one in stock at chaparral. Had them set it aside for me.
In the end, only a $50 mistake in a $2000+ overhaul. I can deal with that.
So saturday (tomorrow) I will be driving down to pick it up, and drop off some items for powdercoat.
The new LH crank seal also comes on saturday via USPS.
I will be paying/ordering the remaining aftermarket items required for this build TODAY. SO....
STAY TUNED... not alot to hold me back at this point. Just getting it together the right way the first time!
-BIG DAN
People shouldn't be rushing you like that... I should be ashamed... really ashamed ! 
People shouldn't be rushing you like that... I should be ashamed... really ashamed !
Shut up smart ass.
OK.
So saturday (tomorrow) I will be driving down to pick it up, and drop off some items for powdercoat.
-BIG DAN
I'm pretty sure the PC dude will be bouncing back, and forth between Pomona, and Ontario for 12+ hours tomorrow. I'm thinking your best bet if you're down here during the day, would be to put your items on his front porch, which they'll be safe there. If you come later in the evening, still do the porch thing, since the PC dude will probably be sacked out on the couch.
That is one frickin' awesome PC dude....I'm pretty sure the PC dude will be bouncing back, and forth between Pomona, and Ontario for 12+ hours tomorrow. I'm thinking your best bet if you're down here during the day, would be to put your items on his front porch, which they'll be safe there. If you come later in the evening, still do the porch thing, since the PC dude will probably be sacked out on the couch.
-BIG DANEDIT: AND GOOD LOOKING!