Rebuild started with engine and swing arm!

We finally got the swing arm bearings in, and installed.  But when we were about to install the swing arm linkage, we found something that I totally forgot about...the bearings in those.  What is it with us and bearings?  Anyway, those are now on order too.  So we have the engine, swing arm and the electrical system installed.  It is starting to look like a motorcycle again!

 Bearing install with our special homemade tool!

Grease the bearing really good!

Bearings installed and swing arm ready to install

A little sanding on the holes so the bolts will fit

A lot more grease this time added to the swing arm pivot bolt

Add a little torque to the bolt

Add some electrical components...and this is what we ended the day with.

Great looking bike so far!

Here is the linkage that I forgot to bearings for.  Just trying to find out how to remove the bearings where there are two in the same opening.

Once the bearings for the linkage come in, we will take it and get the bearing pressed out and installed.  We are still waiting on the steering stem to come back from the Yamaha place so we can install it on the bike.  Hopefully it will be ready tomorrow...fingers crossed!

Steering stem bearing...

Took the stem to our local Yamaha dealership (only choice I have in this town), and they froze the stem overnight and then...they bent the bearing while installing it.  I asked them how they have done bearings in the past, and they said uuuuhhhh.....  I had them order the correct tool for the job (at no cost to me!) and they also ordered a new bearing.  Supposedly will be done this coming Wednesday.   We'll see...

Did some bearing work today...

We decided to tackle the lower bearing on the steering stem today.  The first thing we did was take it to the local Yamaha dealership, of course no technician was working that day!  So one of the guys there tried using a hammer and punch (we also tried that), but all he managed to do was make the roller cage come off.  So back home, I pulled out the Dremel with a reinforced cutting wheel on it.  I cut most of the way through the bearing, tapped it with a hammer and punch, and it broke loose and came off really easy!  I will take it back and have them press the bearing on though, it will just be easier.

Like I said before, we received the bearings for the bike, but instead of the swing arm bearings we received rear wheel bearings.  So in the meantime, we decided to go ahead and install the bearings into the linkage.

I used a set-up I found on the internet to press the bearings in.  It is basically a continuous thread bold with a couple washers, one of which just fit into the hole allowing us to get the bearing flush.   Worked really well, I was surprised!

Be sure to grease it real good!!

Now to apply a little pressure with the homemade press.

  

 Install the dust seals...

And the final product!  Ready to be installed and hopefully never cut out again!

Now its just a waiting game for the swing arm bearings, and then we will be able to install the engine and swing arm.  Make it start looking somewhat like a motorcycle again!

Top end done!

UPS guy was kind enough to deliver some engine parts for us a couple days ago!  Now that we have all of this we can start the top end rebuild.

Upon opening the package, I found out that I forgot a rubber grommet that goes on the left HPP valve.  Order that and now that we got it in, we completed the rebuild of the top end.  Justin had fun doing it, seeing what the internals of the engine look like and learning how to use a torque wrench in the process.

Everything felt real tight on the bottom end, therefore I didn't worry about pulling the two halves apart.  That would have been an adventure all by itself, glad we didn't have to do it!!

Top end removed, new piston and seal installed

Justin lubing the HPP valves

And the finished product...and just by feel, it has way more compression than before.

Bearings for the bike were shipped out today, so once we get those in we will start doing a little assembly work.  Justin and I are ready to see it start coming together!  We should have the motor, swing arm, and front end installed on the next post...I hope!