Brake hose set

Purchased steel braided brake lines with anodized dural banjos by Lightech. The fabrication of the fittings is good, the product is very light and goes well with the overall color scheme. The lenght is adjusted according to the genuine lines. The assembly is quite simple and just a few basic utensil is needed, like sharp pliers, round pliers, small screwdriver and spanner. Some useful how-to videos can be found on YT.

The joint attached to the lower yoke is bacically of no purpose here, it only serves as a make-ready for second braking disc fittings which can be found on "600"

Varia, misc., etc...

(Probably) the last dose of new chromed parts - shift gear, exhaust rings, various screws - mostly from the engine covers 

                                 Spacer ring for rear brake pedal, made of brass

The battle for the tank still goes on...it was cut off again as the previous attempt proved to be unsuccesful -  the left and right side closed inward like an envelope during the welding, which prevented the tank from being installed on the frame...This time, the inward sides were welded solely, first.

Auxillary frame should help maintain an accurate distance 17 cm during welding

                     Cardboard model to help determine the proper shape of the tank

                                                 
                                                     New Sunstar rear sprocket 

Front fender & rear tail cover pearl white paintjob

                                                    Covered with the clear coat

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