Braking elements

As I was dissatisfied with the quality of seals by the major aftermarket parts provider, I eventually decided to buy genuine Yamaha ones. The problem was with the dust seals which tend to splitting while the piston had been installed. OEM is triple times more expensive, however incomparably better. And that's that.

Previously used brake pads in a fairly good condition

Brake caliper pistons & seals

New braking elements - I ordered stainless steel pistons in one metal fabrication shop nearby. It cost me 700 CZK (4 in total), a very fair price for replacement which is even better than the genuine parts - plain steel and chrome plated pistons.

Full set

Caliper seals 

Bleeding screws - stainless M8 for front brake and two dural M7 screws from Lightech for rear 

Before coating, the inner grooves were full of oxidated alloy - I've scratch the corrosion carefully out and polished the space with aluminium polish paste. The seals got to seat securely in its grooves

Application of thick layer of vaseline

Last but not least, here we have a great replica of genuine stickers for rear fender cover - now unavailable - made according to the image found on web and cut from a golden foil on plotter. 

Many thanks for creating the graphical draft, M. Sz!

 

Tank-thing

The tank is back home for Christmas - after the two months spent in one manufacturing company in the town nearby. The result is incomplete, still a workpiece. But it is not entirely bad, I mean, it could have been worse :) Actually, I am surprised. The guys delivered the tank with the welded seams already partially smoothened...Anyway, some welding work still needs to be done, particularly concernig the mounting bracket at the rear of the tank, which we have bended in order to enable the access to the inner side. At least I can get the rust out from there.

I am curious about the check with the tank mounted onto the frame and under the saddle..some reshaping is possible regarding the back left/right corner of the tank.

         

Exhaust pipes & rear master cylinder

There was a small dent on the outer surface of the exhaust pipe -  first, I was considering wrappping it with a heat tape, which is highly fashionable among the builders now, but this solution later seemed to me rather cheap - visually and mostly in terms of renovation. Luckilly, it was possible to reshape the dent after heating it with a heat gun and using a pointed iron rod through the inner side so that no welding was eventually needed.

 

        After cleaning, smoothening and polishing, the pipes regained original look. Surprisingly, the ring on the top of the pipe. where it is mounted to the cylinder, is made of plain steel and not a stainless (as the pipes are). It will be later on painted with a heat resistant colour.  

 Secondly, here is the new kit for the rear master cylinder

Condition of the former inner functional parts was as follows:

                                                       

  Applying a film of the vaseline

Pushing it down

And locking the rod with a circlip

Tank (t)issue

After some time spent resurrecting another ride, here we have bended iron sheets of an appropriate thickness, cut and folded according to the genuine shape (deep bow à mon père). Further step will include welding it correctly to the respective places. Then there are some minor details like polished cylinder head plugs and timing chain tensioner. The rear fender covered with layer of paint for bumpers and attached (it has a texture in comparison to the original smooth surface, but looks pretty well).

 

More rust :)

The bottom of the tank was affected by the major corrosion and hasn't been repaired in a truly thorough manner, using thick layers of brass (the surface also shows many dents, it was probably crashed as well). Today, we simply cut these parts off with an angle grinder...bye bye    

looks like a beginning of the new adventure... 

prior to that, I used this handful of screws and nuts in order to get rid of inner rust. After proper shaking and pouring out

what fun!   

From rust to chrome

...& new mounted parts. The headlight rim was bent and needed some repair. First, I let it de-galvanized and then gave it a bit of tinsmith treatment. Once it was straight, I sanded the piece and let it chrome plated again.

together with another chromed parts

the only powder coated bits are the front fender mounting bracket and the sidestand

finally the much-favoured "cafe" look 

airbox unit, rear fender, CDI, oil tank and brake fluid container added