Semi faithful, ground up restoration project!

[Wolfman]

Ok, well it's been a while since i updated everyone on this project, and it is now a lot further advanced, in fact, i am about 2 weeks away from having the bike back on the road.

I have a complete rolling chassis, only thing's that are missing and the Motor, and the Exhaust system.

The motor re-build is about 2 weeks away from being finished, and apart from the exhaust is the last piece in the puzzle...so to speak, apart from tuning the bike, once it's all back together, and full of all required fluids, etc...

Now, the motor...Ok, this is the final "spec" for the motor,

All parts OEM other than where specified.
New Crankshaft.
New big end & main bearings.
1 New Rod.
New Camchain.
New 1mm overbore pistons.
New piston rings, gudgion pins, etc.
A new set of Valves...all 10!
Aftermarket complete Gasket & Seal set from Germany.
OEM Yamaha 1mm Overbore Pistons
Camshafts sent to Ivan Tighe camshafts for a bit of "black magic" re duration, and lift etc... Cams got sent back, with a new set made, with increased lift, longer duration....

That's the parts....

Now, here is the good stuff, the engine mods...

Obviously, oversized pistons, which bring the engine capacity up to about 868cc i think?
Then the Head is being poilshed and ported, with a valve grind, and a bit of work done on raising the compression ratio, along with the camshaft work...

So the top end rebuild is all about gaining better performance, and freeing up some hidden horsepower...

The bottom end re-build is a just a standard rebuild...nothing special being done to the crankshaft...

The motor is also being given a visual facelift, with the rocker cover, Oil Sump, and Cluch Cover insert all being refinished as brushed metal, and the rest of the motor is being painted a low sheen, satin black...not a matte, but not a gloss, a satin! (I had to be very specific about this!!!), so the motor should look new, like the rest of the bike!!!

Then the exhaust system is being fabricated from mild steel, with 41mm, 44mm oversized headers, exiting into a single shorty GYTR race pipe on the right hand side of the bike...the GYTR race pipe is 50mm in diameter.

This is a change from a 38mm OEM header, with a 2 into 2 pipe arrangement, with two long cans exiting from either side of the bike.

I am also getting a baffle made up for the GYTR pipe, cause i suspect with such increased breathing, the bike is gong to be pretty loud....it was before with the twin unbaffled Staintune pipes...so with a single shorty pipe, of increased bore, in mild steel, it's going to be loud! So ceramic coating on the inside and outside of the headers, and a baffle, for normal street use, will be used to calm the noise a bit.

All this, coupled with a new K&N airfilter, reconditioned, and dynotuned carb's, we are looking for a final output of somewhere near, or hopefully a little bit over 90hp at the rear wheel, which would be a a big leap from the 76 -80hp that is on tap in OEM form.

This coupled with a massive weight reduction in weight, removing the big, old, heavy headers and twin exhaust pipes, and going to the lightweight 2 into mild steel, and short, ali GYTR pipe, there is a weight saving of about 14kg's, or something stupid like that.

I have recently put a new solid black racing screen on the bike.

Repaired the mirrors, and re-painted them Satin Bumper black....they look better than new IMHO!

Replaced front aftermarket flush mount indicators, and rear OEM indicators, with matching Oxford LED stick indicators, in a diamond shape design, which suits the bike era very nicely....i also painted these indicators the same satin bumper black as the mirrors.

The underseat tray, which pokes out under the rear seat unit, and becomes the rear fender & number plate holder, has also been painted in the same satin bumper black as all of the above, as has the Front sprocket guard, and OEM chainguard.

I also modified (with a fair bit of brainstorming help from Mikey), a Carbon Fibre R6 03 front fender....looks schmick!

I have had both the Rider & Pillion Seat Recovered, in black, leather look vinyl.

The Renthal 40t (+1) rear sprocket is sitting there ready to take the DID gold & black chain...

All new cables are now on the bike..clutch & throttle...

Replaced all the instrument panel globes with LED replacements....3 of the 8 were blown anyway....

At the moment, the bike is sitting on the bench in my shed, with a motor in it....not the one that is going into the bike, but another "spare' motor i have for the bike, sorta came with it, it's had a big end failure as well....in fact it is the bikes original motor...the lump i am fixing is the third motor i think....anyway, this i put in the bike tonight, so that i could send the bike off to the exhaust fabricator to get him to fit up the headers, and GYTR pipe....once he has done this, i will drop this motor out, take the bike and exhaust system to the shop that is building the motor, and get them to fit the rebuilt motor up with the new exhaust, so they can then start the bike, run the bike, put the bike on the dyno, and tune the bike....this as i said at the start of this post, should happen hopefully within about 2 weeks!!!!

No more photo's, i am gonna let ya's hang out till i have got the bike on the road, and i have got the final hp and torque figures, and exact specifications of the engine mods....

[Mincehead]

Nice!
Cheers for the very `complete` update Wolfman.

[Wolfman]

Nice!
Cheers for the very `complete` update Wolfman.

Actually it's not quite a complete update, the bike is now at the exhaust shop getting it's headers fabbed up.

Once the headers are fabbed up to link with the GYTR pipe, then it's off to the ceramic coaters for the headers...

The Motor is nearly re-built at the engine shop....just waiting on a new set of valves from Japan, found out yesterday the the valves that had a regrind, must of had a regrind once before, cause there was clearance issues after this re-grind...valves are ordered....

"new" front fairing, and seat unit should be here early next week.

[alextrx850]

firstly i think you need to be re-nameing your project thread "bloody amazing ,ground up resto project."..looking to the photos soon,be interesting to tally those reciepts..and what country are you in pls.

[highlander]

Sorry - point of ignorance: why the ceramic coating inside and out of the exhaust headers?

Damn I'm envious of you lot who have way better knowledge and motivation than me for interesting and involving mods .... I just discoverd that customfighters forum. I have already spent hours in there admiring some of the really cool resto/fabriscation projects (and ignoring some really shonky ones too)!

[Killerwhale]

Sorry - point of ignorance: why the ceramic coating inside and out of the exhaust headers?

Damn I'm envious of you lot who have way better knowledge and motivation than me for interesting and involving mods .... I just discoverd that customfighters forum. I have already spent hours in there admiring some of the really cool resto/fabriscation projects (and ignoring some really shonky ones too)!

Keeping heat in em for faster gas flow, like those bandages...but more 21st century.

[highlander]

Keeping heat in em for faster gas flow, like those bandages...but more 21st century.

New one on me! That must be a very minor boost in special (racing) circumstances.

[Mincehead]

Many of those ceramic coatings will also stop unsightly blueing or colour changes in the pipe that folk don`t want to get too.
Me, I like blueing personally, and wrapping headers is for rat bikes only as far as I`m concerned.

[Wolfman]

firstly i think you need to be re-nameing your project thread "bloody amazing ,ground up resto project."..looking to the photos soon,be interesting to tally those reciepts..and what country are you in pls.

LOL! Nice words. Cheers.

As for a running total, i have a spreadsheet that tells me that i am over $11000 out of pocket....Yikes! But i will basically have a "new" TRX when i am done, there aint much left that i can do, in terms of resto work...

I am in Australia, Adelaide to be exact....not the most exciting place to live, but the roads are awesome! Adelaide Hills...FTW!

[alextrx850]

you have done all i could think of except some iridium spark plugs..a nice job..especially to the heart of a trx which i think is the motor and frame..money well spent, [especially being yours. ] and they arnt getting any younger !.
A lot of info is leaning towards a tdm 900 motor these days with the TRX heads, but the horse power [little of it ] to a tuned TRX seems lacking for the change and then, would it be a TRX [really]..im thinking you might be a bike mechanic...OH and cheers for flying the aussie flag.

[fung]

Hiya wolfman !
Just so you know, we all here on the forum love to show off what we have done/are doing/will be doing to the ubiquitous TRiXie.
Any photos of your beast throughout its transformation (not just the finished product ) would be most welcomed.
there are quite a few threads on the 'how to' when posting pix.
So well done and welcome to the forum.
cheers
fung

[kenmore]

Way to go.

I am hoping to do a similar project shortly.

I rebuilt a mates Trx engine a couple of years ago, and the cost in parts alone for that was $2300-

It had also spun a big end bearing due to oil starvation. The bloody thing was a mess and all up cost approx $3,000- with machining and a few odds and sods.(We managed to machine the crank and match it with some bearing shells from a 202 Holden Red motor that the edges had to be machined on to remove a lip. ( This engine is still running and has not missed a beat and uses little or no oil.

Are engine parts hard to source ?

I intend to go down the big bore road if that is still possible.

[SDN]

Pics please!

[Wolfman]

Ok, photo time....Engine before re-build



Ok, not quite re-built, but with a paint job, some metal brushing...decided to brush the "fins", to break up the blackness, and to polish rocker cover, oil tank lid, and clutch cover insert...all the brushed metal should go well with the brushed swingarm, sub frame, and Coerse rear set's...

[Wolfman]

Some photo's of the bike with the original seat & fairing unit on it, obviously, there is no exhaust or motor in the bike at this point, but you get an idea of how it is all coming along.