1977 yamaha 650 d restoration files

[lawrgj]

Found out the shipping co. Is dElivering my new toy two days ahead of schedule, Tonight! So begins what should be a highly documented thread about the resurection of this once great machine.
as soon as she gets here i will start photo's
Thanks dad i love you

 

[lawrgj]

recieved my bike tonight! first things first, remove the damn luggage rack.

 

[pregrid]

This is NOT gonna work without pics!

 

[nj1639]

This is NOT gonna work without pics!

Hear hear! Where?

 

[lawrgj]

Just found the engine is seized... bad news bears for me

 

[nj1639]

Put 4 or 5 ounces of Marvel Mystery oil or some penetrating oil of your choice in each plug hole, let sit overnite and then hit the crank nut with an impact wrench, quick short bursts. Don't jump up and down on the kick starter, could bugger something up.
I used a breaker bar and a rubber mallet to free mine......just took a few whacks....

 

[lawrgj]

Today is a new day, lets see if I can get some more pics up and get her to turn, I left a lot of fluid in the cylinders last night... If not, i hit something with a hammer and start tearing her apart

 

[lawrgj]

Well, she is seized up fierce..... that engine better be ok jeez there are only 2000 miles on it. here are some pics of today,
got the exhaust off and out of the way, had to cut the crossover,
got to look at the valves, looks noce and clean in there,
exhaust ports are super cruddy
intakes are fine
the carbs are off and seem to be in decent shape!
whats the blue wire on the engine block

 

[lawrgj]

PICS sorry about the cam

 

[Mister Mellow]

It would sure be nice if you didn't have to tear the top end off. As long as the plugs are out, I'd be generous with whatever you pour in there. I've used Marvel Mystery Oil to loosen up engines. When I was a kid, I broke an engine loose on a Trail 90 by putting it in gear (spark plug out and cylinder well-soaked in MM Oil), and sat behind the bike jerking the wheel back and forth. I took a while (10 minutes or so), but the engine finally moved. Of course, you're working against a lot more engine, but it's worth a try.

The blue wire. Do you mean the one behind the left cylinder? That's the neutral indicator switch.

 

[Mister Mellow]

By the way, the bike may be dirty, with some rust here and there (it looks like mostly on stuff you'll likely replace anyway), but it looks to be in pretty good shape otherwise. I predict smooth sailing, once you get the engine sorted out. Nice gift.

 

[lawrgj]

yeah the bike was stored for thirty years only 2k original, and everything is accounted for other than the alternator cover, the left points cover, and the headlight and bezel... I even have the owners manual full tool kit and bag and the owners id card from yamaha

 

[lawrgj]

Still waiting to see if she will turn, luckily sseres who wrote and documented his overhaul lives down the street it turns out

 

[DLD1]

Looks like a fun project. Keep the photos coming!

 

[lawrgj]

IT MOVED!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! I was rocking it back and forth, all of a sudden i felt something give and stopped to look at the timing marks, moved about an inch! then looked and saw the advance and points were shifted, then realized that the opposite sides valves were open.... then looked in the spark hole and the pistons dropped and I see silver! maybe tomorrow she will turn easier

 

[XSJoel]

Let that Marvel Mystery oil sit in there and soak in good for a few days and it should come unstuck.

 

[lawrgj]

ok so just rockin back and forth in 3rd 4th and 5th right now every night, stll pretty stiff but I assume she will keep getting easier

 

[VosaME]

Awesome! Glad to hear she popped loose! If you need a second set of hands or any tools or anything let me know! I am an aircraft mechanic so have or have access to anything you might need

 

[lawrgj]

SO... started tearing into her this weekend, after the engine was free, I Started to disassemble, here are some pics.
I plan to get to the bare frame this week, start wire brushing and grinding to clean her up then its time to paint the frame!
I know I will catch hell for this but I think i am going the primer and rattle can route, I know how to paint and I figure a 5 day cure in direct sunlight will be ok

 

[pregrid]

Keep in mind tho the engine is now freed up you're still gonna have to do a top end job.