Yamaha YSR "The Pole Smoker"

[Shakotom]

This thing was rad at TeUruweraAdv. Great adv bike.

 

 

post us up some beauty shots with the full fairings on please!!

[cletus]

I was so amazed/stoked that it made it the whole way  

 

Also your undercarriage must be made of titanium , the seat did not look comfortable at all  

 

[Duke Blackwood]

So I’ve been busy beavering away quietly on the pole smoker... I’ll save the progress report until I have a decent photo, but the shifter shaft is still the most pressing issue. I had to straighten it to remove it and found it was also bent IN the engine itself. I stripped my spare engine only to find it has a huge groove right on the oil seal surface of the shifter shaft. I enquired with a mate about metal spraying it and machining it back but even at mates rates it’s $120 clams... the bike still only owes me like a Hundy. Anyone have a TS185 wrecking? Or know if the mud bug shifters were compatible? Once this is sorted I’ll need to do the seal, reassemble, and get new sprockets. I will make last years sprocket into a medal and wear it with pride.

[flyingbrick]

Dont metal spray it. Just tig it up and have ur mate lathe it smooth and then polish with paper till its shiny. Will still be better than any used shaft. 

 

[Duke Blackwood]

Y’reckon? There’s a tig and a lathe in the shed (so I can do that for free) but the yarn was that the heat would corrupt the shaft in that area, so it may become more prone to bending... or snap.

[chris r]

It's already bent/fucked right? so nothing to loose except time imo. 

[tortron]

Pick the right filler and then case harden it on the bbq

 

Or lathe it down and loctite a speedy sleeve thing on it, are those available for shafts?

[Duke Blackwood]

Im not at all worried about destroying the shaft; it’s fucked. I DONT want it to fail during this years Te Urewera Ride haha. If I was just putting it back on the road I would TIG it but knowing what I’ll be subjecting it too... I don’t want it to be next years week link as well.

[tortron]

Got a press? Could spend an hour or so manipulating your shaft to work the kinks out

[flyingbrick]

9 hours ago, tortron said:

Pick the right filler and then case harden it on the bbq

 

Or lathe it down and loctite a speedy sleeve thing on it, are those available for shafts?

Yes,  as small as 12mm

[Duke Blackwood]

Lads I have tigg’d the shaft and tomorrow night will machine flush, last night I pulled the seal to source a replacement and found this....

(Image of aluminium, hanging like sleeve of wizard, I don’t know how to implant images)

The shaft has elliptical-ised the hole which will presumably be detrimental to future seal life. 

what are my options?

Bore out hole and press in sleeve? Not easy. Would have to be dead straight and no doubt will get Swarf in motor.

machine a washer to sit in the seal groove behind the seal, centralising shaft, floating in the stretched ali? Dead easy, but will ultimately cut through the shaft because  of the thin surface area.

press a sealed bearing into the seal groove and run with no external dust seal? Is that even a thing? Could that work?

this hurdle is the only thing between me and powdercoated re-assembly... there are other bits to do (I wanna try Blizzos LEGO welding trick) but when I get a seal I’ll be back on the road!

[tortron]

jb weld

can also powdercoat jbweld if so inclined

 

you sure you cant plug it and machine and press a sleeve in tho

 

oh you could totally press a sealed bearing in and run no dust seal, thats what GN front wheels switched to

[Duke Blackwood]

I hadn’t considered that... If I could be fucked splitting the cases I could Ali weld it and then redrill it, but a gasket set is probably worth more than another engine and only a shade less than another bike haha total bike cost still under $200!

And I’m also reluctant to plug and drill it for fear of not nailing the alignment...

But i could do a combination...

1. Washer in seal groove

2. JB weld hole edge

3. Drill JB using centralising washer as guide

4. Sealed bearing on top of centralising washer

5. Celebratory burnout?

I have just given the triple trees the quick polish they missed before last ride too

[Duke Blackwood]

This image also features:

A crate of speights 

A copper home-brew setup

A sword

A Cordia bonnet scoop (Destined for a MK5 Cortina, when I get one)

A wall mounted CBR250 tank and exhaust

An old dutchman’s Chopping axe

And toolbox racing stripes

Edited August 26, 2020 by Duke Blackwood
Realised it was funny

[Duke Blackwood]

Might need a new front sprocket too....

[Duke Blackwood]

From 9mm seal to 5mm seal and 4mm support bush. Shaft welded and true.

[Duke Blackwood]

So last night I attempted reassembly with the repaired shaft and seal/bush combo but I just could not get the side cover back on; something wasn’t right. Turns out the shaft I repaired was from my spare engine, not the one that came out of this engine, and it has a boss on the backside of the shifter return spring that was a ducks doodle longer than the original. At this stage the clutch basket and everything was reassembled and it’s one of those STUPID pricks with little hard pins that you slip under trampoline springs while trying not to stab bucket Barry with a pair of long nose pliers while palpable tension rises in the shed and no one will smile for fear of chipped teeth when the pins fly out.... 

So yeah we weren’t taking it apart again to machine the boss off in the lathe. We found out what it was binding on. There was an ali tang, protruding from the cover, to meet the shaft at the back and negate end float. This tang was an afront. As I loaded the meat axe blade into the grinder, bucket Barry produced a mean right angle dremel cutting tool which did a really tidy job of shortening the tang.

Side covers on, press in bush and seal, done. Then bucket Barry pipes up.

”That seal went in tooo easy and I think it isn’t deep enough, I don’t think it will seal. Pull it all apart and we’ll machine some depth off your bush.....”

Well we aren’t doing that. I’m gonna replace the seal with one the same; but I’m gonna put it in covered in liquid nails. Better living everyone.

[Duke Blackwood]

shed night last night = begin general re-assembly. It’s slower than stripping the bike. Applying never-seize. Applying loctite. Taking care no to scratch my new powdercoated frame! I am enjoying the process though, I don’t think I’ve ever put anything back together like this? Typically when I’ve stripped stuff.... it was terminal. 
 

Got the swing arm mounted and the forks. The polished triple clamps look grouse but my castaway style improvised steering head bearing setup and the need to shim around the forks where the triple clamps bite, made it particularly slow going. On last years ride I punched the forks up through my homemade clamps fording a stream at speed and I’m hoping to avoid that experience in future. I also ordered some tyres this week from our main man @MopedNZ and I’m super excited to receive them (Despite bucket Barry routinely advising me that They’ll make a bike which is already difficult to ride, MORE difficuilt-er).

Edited September 10, 2020 by Duke Blackwood
Fucking autocorrect

[Duke Blackwood]

[Duke Blackwood]

Guys why don’t my pictures upload in the correct orientation and how do I rotate them? I am new to the internet. I’ve only been using it, like, 20 years. Shed night this week. @anglia4 3D scanning the pole smoker so a proper spannie can be developed to fit in that tight fairing recess.