kdotlowe

Good to know! @Lord Gruntfuttock Cleaning up the rims as we speak. What's everyone's thoughts on the rust situation? I've ground it back as much as possible and treated it with a converter. The spoke holes are all good. Think this will be an issue?

Yeah a few were seized on good! I think I'm just going to replace them all. I'll happily pay the money to avoid having to clean & polishing the good ones here haha. Will measure up and check Ali.

Well that sucked. Broke a few spokes so I may as well have cut the bastards off.

I know this is going to be a pain in the arse, but I'm attempting to re-lace the wheels with new spokes and nipples. Removed the old dry rotted tyres, bearings and starting removing the spokes. There's a fair bit of rust in the rims but the nipple holes seems to be pretty solid so I'm not too worried.

Turns out the switches I ordered are slightly different to the OEM ones. I don't want to have to rewire anything so today I set out to restore the originals. Happy enough with how they came out. The switches now 'click' much better than before.

Well that's it, the engine is complete. Just need to get a small enough torque wrench to torque down the head. Going to wrap the engine up and keep it stored safely while I make a start on the rest of the bike.

Few more parts from China. It's all so ridiculously cheap it has to bite me in the ass later on down the track. $14 for a set of control cables, and $25 for the switches.

Good to know. I think because the tank requires some minor bodywork paint might be the best option. I don't really want to try colour match paint to powder.

Making a start on the bodywork. Pulled out the swing arm and lower shock bushings which was an absolute bitch. Using a ghetto method of hot glue and a socket extension to pull out some of the tank dents. It's surprisingly working. What's everyones thoughts on powder coat vs paint? I want a good finish and the frame, side covers and tank will all be colour matched. Is powder or paint cheaper? (I suck at painting so don't want to do this myself).

That was vapour blasted - well at least the head was. Done through a guy called Darth Vapour.

Look what we have here. Had to do a mock up after painting the cylinder and head. Off to the machine shop tomorrow.

The end is in sight! Blasted head and cylinder. Once machined and installed the engine will be complete!

Shout out to Yambits! +0.75 piston arrived alongside and new small end bearing. Cylinder and head are off next week to get blasted. Once painted the cylinder will be off to the machine shop for a a fresh bore & hone.

$15 dollar exhaust arrived and it looks just as you'd expect - like a $15 exhaust. I'm happy enough.

Gave the wiring harness a once over. Other than a few crusty connecters it was in surprisingly good condition for the age. Also cleaned up the air box ready for some polishing & powdercoating.

@Truenotch cheers bro! Looking forward to your build thread! Got carried away and installed the points/magneto. Realised that I need to find a replacement side emblem, mine is bent to buggery. Also placed an order with Yambits for a 0.75mm oversized piston. Toyed with the idea of going 2mm over, but I think I'll keep it conservative for now. Once the piston arrives I'll send the cylinder off to get a re-bore and hone.

I've been busy. Missing one titanium bolt which is heartbreaking but hey, that's the right side done for now.

Clutch plates all installed. Oil pump assembly installed. Love installing parts when they're all clean & freshly painted.

Found a box full of misc parts which contained some of the parts I required - the joys of building an engine from a box of parts. There's a few variations of the YB100 with mine being the earlier model. Seeing as this engine was in pieces when I purchased it, I'm not sure if a piece I can't find is missing or just not needed. Currently referring to 2 seperate schematics and unfortunately my engine seems to have pieces from both... Installed the kick start shaft after a bit of fluffing around with gear orientation. Also installed the clutch basket. Turns out my clutch plates are at OEM measurements. No wear on them at all. I'll be using them again so I've left them in some oil to soak overnight.

Cheers bro! All a learning experience for me so here's hoping it runs!

Sourced some Threebond and sealed the cases. Installing the disc valve cover & gear selector. Looks like I'm missing a bunch of circlips and other misc hardware. Will have to dig around the box the engine came in to see if I can find everything before I can continue.

Titanium bolts for the side covers, for no reason other than they look sexy.

Tried that. Unfortunately all out of stock. I was pushing my luck and hoping to get some today haha!

Tusk crank puller tool arrived today and made easy work of installing the crank. Not a cheap tool, but I think it will pay for itself if I'm rebuilding engines frequently. Can't seem to find any Yamabond locally and Threebond is ridiculously expensive so I may have to order some online before I can seal the case halves.

It's Christmas time and I'm poor so I'm waiting till the new year before I splash out on some crank installer / case splitter tools. In the mean time I've been cleaning and painting bits and pieces to keep the progress going. Oh and I bought a brand new exhaust header & silencer from China... FOR $15. Postage is around $80, so less than $100 for a brand new exhaust - I wonder if it will actually fit?