First time out

Today the bike saw the daylight for the first time in almost six years. It is nearly completed, only one exhaust pipe is missing due to seal which needs to be ordered. Therefore, I haven't tried to start the engine yet. The expectations are high :) Also, Yamaha emblem on the tank will complete the whole picture, soon. 

                                               
                                              with a bigger sister XS 750

Tank paintjob

This is the first check with the new pearl white painted tank. Some small parts like turn signals and the new battery added.

Engine covers, carburettors etc.

Hey, here is the latest bits fitted on the engine including carburettors with the new o-rings and gaskets. New bits on the block also count shift shaft; switching the gears now runs smoothly. So does the clutch and throttle cable, the only enigmatic thing remains the cable of decompression cam, lifting the valves during kickstarting. The new cable and the spring are in the right place, however the lifting doesn't occur and will take some more figuring out.

Engine installation

Some significant milestone here! The single thumper is seated back in the right place. During the initial installation, the engine is not supposed to be attached onto the frame using the tube cradle, as I thought before. First, it needs to be hang up from above and backside to the respective brackets like with a typical backbone frame.     

Lifting the engine on a jack, reminiscence of Laverda-like slope and a gearing cascade

Lower cradle tubes and generator rotor attached  

Plus clutch housing

At this point, the dog who appears to be of pitbull descent concluded that the assembly is going way too smoothly and decided to trash the plastic front wheel hub cover (the plug). He has already trashed various sort of things, from mp3 player, sunglasses to book by Remarque (in order to affirm himself in his far-right determination). A painfull loss, the part is unavailable as OEM and had been previously welded and painted up to the satisfactory condition. Luckilly, I spot a used part by breakers on eBay which is currently in transit.   

Latest batch

A fresh update with cylinder head and valve assembly

   timing chain with markings alligned (new OEM Yamaha part is surprisingly less costly then DID and other aftermarket brands)

Polished tensioner with chromed nut

and the valve cover attached

Piston + cylinder put on

We had to source the head gasket for 400cc which is discontinued; Kalina Industries from Zlín helped a great deal and manufactured an affordable replica from their portfolio. A broad variety of manufacturing machines and a great customer experience. Highly recommended.

Wössner piston set with gudgeon pin and piston rings seats ok with

an adequate clearance

OEM cylinder gasket and Oring

Installation with lubricated barrel and rings pressed inwards went rather smoothly

Moving

Big day in fact, the chassis has left the warmth of living room after few years for its journey to an engine transplantation. More about this logistic problem below.

Ok, this is the crankcase mounted in the bottom cradle; the engine is hanged from above by a gudgeon pin, otherwise it would have flipped forward. The key to this ingenious suspension actually is a norwegian wooden block.

Well, if you work on the chassis in the first floor, you will eventually face the issue how to fit it with the engine that is being completed in the garage...hm, then the funny things occur and the maiden voyage rather reminds of a trial bike session 

Staged comfortably

..to be continued