Engine rebuild

Time to put all the refurbished parts back together.
New gaskets go on under the cylinders.

Cylinders with top gaskets new seals etc, etc

The timing mark lined up to get the cam in the camchain in the correct location.

Cam chains in their correct location, I couldn't get a picture of the markings, but they're in the Haynes manual.

Finally the cam chain tensioner gets put in to get the correct tension.

Cylinders back on and all torqued down.
Intake boots with rubber gaskets instead of card ones supplied in gasket set.
Engine now ready to put back in the frame.

I have at this time got the bike back together and have started her up, just need more time spent on this blog bringing it up to date, more pictures to follow , keep tuned folks.

Regulator/Rectifier relocation.

With the heat build up of the R&R beside the exhaust manifold I decided to relocate it in fresh air. I used a bit of stainless plate cut and drilled to shape.

The plate with the R&R on the back of it.

The R&R bolted to the plate with stainless dome head nuts to finish it off.

The R&R and bracket in place on the bike. Its bracket is fixed on the engine mounting bolt which I remade with threads each end rather than a bolt and put domed nuts on each end.

Oil filler, stator and Regulator/Recifier

I intend to put the fairing that came with my purchase on the bike but not all parts were included for the full adaption.
One part missing is the adaptor that replaces the oil filler cap that fits an oil tube which extends the filling to fairing bracket.
I can't find anything close on ebay so I had to find something else.
I did find a 1/2" BSP tail fitting on ebay which is a fairly standard part for hose fittings.
Only problem is the thread in the casing is metric so this was tapped out to 1/2" BSP.


The fitting as it came from ebay, fairly cheap as a used item.

The fitting screwed in place. It has now been shortened, I'll post another picture with the hose attatched when I've taken one.


The connections and sleeving on the internal engine electricals get updated next.
I bought a 3 way waterproof electrical connector off ebay for the connection between the R&R and the alternator.

The connector all fitted.

A picture of the R&R which came off the bike, soldered wires and hardened sleeving needs replacing. I found on the internet that this one comes off a Yamaha XV535, original ones tend to burn out due to the heat they produce and they are loacted in an enclosed space close to the rear exhaust manifold. I'll post another section of how I dealt with that.

The finished article with new connector and heat resistant sleeving (thanks to Mike and Chris) .

The other internal electircals also get tidied up.