What did you do today? Cobba's rebuild

[cobbadiggabuddyblooo]

Quick update on things,
I drove Rod crazy today with the constant click , click, click of the torque wrench as I finished off the rolling chassis so tomorrow is bleed the brakes and begin to place Kev's old motor into the bike to get myself mobile again.


As for the motor, well the crank is in place with rods fitted, gearbox in inplace after finding I had 4th gear on back to front Thanks Rod after you where watching me scratch the skin on my head..
The selector fork would fit onto the gear ok but when the selector drum was fitted I couldn't shift the gears even tho all slipped in ok with the gear back to front
4th gear lives on the end of the drive shaft and when you pull the gearbox apart ,this gear is not fixed on the shaft and slides easily off so a handy thing to remember if you ever pull your gearbox apart.
So there the motor sits until I get the top end parts back again and the new crankcase bolts to lock it all together.

[sanddune51]

On the home straight now Cobba, hopefully not too much further to go


Mark


edited to correct my spelling of too

[cobbadiggabuddyblooo]

Thanks Mark.
Just been chatting to Jim over in the UK from JT sprockets as I'm chasing rear sprockets and looks like I have a bit of an odd ball hub which they only released for a couple of years.
and more than likely just when dymag went into receivership early this century.
I had to space and modify the wheel spacers as there was a 2mm gap between the cush drive hub bearing spacer and sprocket carrier bearing spacer which obviously caused the bearing problem once the wheel was tightened at half spec.
The std set up with the 2mm gap applied sideways pressure upon the cush drive bearing because the force when tightened could not transfer all the way through the spacers,bearings and crush tub in the centre because of that gap.
New bearings and spacer mods all spins good once tightened now.
Now I'm just waiting on new cush drive rubbers to arrive so prob won't be mobile till mid next week.

[cobbadiggabuddyblooo]

Slow and steady wins the race as they say... Rod has returned from his week away so I put in a few hrs over the last couple of days.
Electrics .
I tried another 4 way ignition, not just 1 power in and 3 out like first time.
This 4 wire has 1 power in and 1 power out and the other two break another circuit from wire 3 and 4 when turned on..
I had power to everything but only 1 single spark from 1 plug and only that 1,then nothing..
So 3rd time lucky, 1 power in 1 power out and the other 2 wires complete the circuit when key is turned on.. Yay..
This completed circuit from wire 3 and 4 joined is the one that initiates allowing a continual signal path from the ignition pick ups to the ECU.
If someone tries to hot wire your bike by just running power from the battery to your ignition wire , this is the safety net yamaha has put Inplace.

So power to all circuits and motor turns over and have continuous spark on both pots when cranking.
So radiator inplace, carbies on and exhaust... BUT
Where I have mounted the dash is fouling the throttle cabling when turning the bars...
So I'll make another mounting bracket and instead of mounting where the old dash used to sit, I'll mount it off the front of the top triple tree.
I fitted a 60* - R6 throttle too instead of the std 78* std TRX throttle for a quick response so we'll see how that goes.
Fitted the new cush drive rubbers and locktite and torque the hub so just about ready to roll.
Clip ons all adjusted and set to give me clearance and comfort and end of another 2 days work.

Fluid day tomorrow filling radiator,changing hoses from M/C to reservior and start the bike with Kev's old motor inplace and then make new mounting brackets for the dash.
So fingers crossed I can be mobile Thursday just before Rod goes on holidays again for 2 weeks...

[Con Rod]

looking good Cobba, great project. Not gonna give you much rear wheel horsepower without a chain though

[cobbadiggabuddyblooo]

No but it's a weight saving I'm used to pushing it Round

[M.V.]

Looking good Cobba!

Is the R6 throttle a straight swap?

[cobbadiggabuddyblooo]

Thanks guys,
Didn't get too far today..It was the old leaking rubber O ring in the thermostat housing trick that bought things to a Holt and late Friday is the earliest Yamaha can get one to me..
Chain and sprocket cover mounted so got something done before taking the car in for a service this arvo.
So make the new mounting bracket tomorrow for the dash and front reservoir.
The clip ons have a hollow tube cut to length as the handlebar with a bung in each end so I'll mount the brake reservoir to the inside end as it protrudes about 30mm past the clip on mount and front fork so similar placement as the std set up..
I actually wanted to mount the rear reservoir further up under the seat but tracking down hosing that will withstand brake fluid is becoming a real challenge.
So close but yet so far..

[Stu99]

Have a look at this Cobba.
http://m.ausfr.com.au/productdetail.mobile?id=126
You can probably get it cheaper elsewhere though. From memory it is a Tygon product, but I'm not 100% sure on that.

Also google Tygon 2075 and Tygon 2375.

[cobbadiggabuddyblooo]

Cheers again for the link.
I found some in the U.S. on ebay of all places .It's black hose and only $3 per foot so got 2' of 3/8 for the rear and 1' of 5/16 for the front .
I'll just place the std reservoirs back on till it arrives.
But the clear looks pretty sexy and the small clear tube on the rear is all you need as I very rarely use the back brake..

[Stu99]

Good find. $2.50 per inch gets expensive when you need to relocate a foot or more. I've seen a few bikes set up using a length of hose as the resevoir both front and rear. Looks trick, but I still prefer at least a mini resevoir for the front. Rear brake wouldn't bother me though, as like you, I rarely use it.

[cobbadiggabuddyblooo]

YAHOO.. Up and running today and had my first test ride. Quick lap around the block. OOps forgot to put the number plate on, another lap and back the compression off by 2 clicks on the front end.
Time for a 5 minute run and came back all smiles.
Straight away Rod pulled his bike out and said,quick go for a ride on mine as a comparison to a stock TRX850.
I rode out of Rod's driveway on his bike,and did a quick zig zag to head down the road adjacent to his drive way, and straight away had to force the bike to turn
30metres down the road and their is a sharp 90* right hand corner and after struggling to pull the bike around as it felt like it just wanted to stand up straight . I stopped around the bend,turned out and rode 200metres back to Rods place.
The light weight wheels have totally transformed the feel of the bike and all I need to do is just think about going around the corner and it effortlessly just does as it's told .
I can honestly say,if you want to improve your TRX, after an ignition module ,I'd be going for lighter weight wheels and suspension mods.
Kev's old motor fitted into my frame is std with about 130,000km's just with my FCR's and Akra system but the handling gains I felt with the wheels I can only advocate this as a serious thought to anyone who wants to improve their TRX.
Tomorrow I'll just have to tidy a few things up and calibrate the dash as 3000rpm in 3rd gear at present shows up as 168kph.. and get the indicators happening properly. And I spose give it a quick bath..

[Rod.s]

Those photo's are a bit blurry mate, were your hands shaking

[Tarwetijger]

Good that you are running again.
Agree with you in the light wheels. Too bad they are hard to find and get, as I want to stay with the original rim sizes.
What wheels are you using?

[cobbadiggabuddyblooo]

I ended running a Dymag SB5 rear and Duomo / Carrozzeria front . Both magnesium and saving me over 5kg.
I still have the Hi Point / Carrozzeria forged aluminium rear that I originally was going to use.
Even that rim is just over 2 kg lighter than the std rim.
I was using Rod's battery to start the bike ( std Yusaka) and once the bike started after 5 or 6 seconds , I replaced it with the new Lithium battery I have and it feels around 2 kg lighter.
There is just under 20kg saving in the wheels, battery and exhaust and pegs alone.
I'll weigh the bike on the week end and guesstimating somewhere between 180-185kg with a full tank .

The 60* r6 throttle works a treat and with the ignition it's still easy to ride in traffic, no problems.
You can still use your std Trx cables that come with FCR's too so I'm betting the std Trx cables with the std vacuum carbs would work too.