STANDARD issue…. a resurrection begins….

Was it wet with oil inside? That oil seal is one of the few you can't get from Yamaha anymore, I think Mike's is the only option.
 
I’ve got a leftover Athena kit I believe. I checked but all I had are o-rings. Everything was significantly smaller too. I’ve been searching around too. You can find some on eBay for around 15-20 bucks each :cussing:.
I did find these though and an considering it.
https://www.dbelectrical.com
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It looks like a great deal for all the pieces for $34
 
I ended up ordering the starter rebuild kit above, but I found it on Ebay for $5 cheaper and free shipping. Everything looked good, but the brass bushing for the shaft end does not fit. Not a big deal as mine is not worn out, but it could be bored or sanded to fit though. The down side is that one of my thrust washers grew legs and disappeared. I've looked everywhere. I am shocked this happened as I was very careful in the disassembly. Of course it is an unavailable part from Yamaha, so I am working on options for replacement. Currently I am sanding/filing down a standard flat washer in hopes to make it work. But this thrust washer must be only about 1/4-1/8 the thickness of the flat washer, so my fingers are pretty worn and achy right now. I've still got a little bit to go as when installed it does not allow the starter to rotate. On the positive side, I can take apart and reassemble a starter pretty quickly now...lol..

I also started on my front brake. It was pretty dirty, so a good scrubbing with mineral spirits and a toothbrush has it looking better. After popping the piston out, it looked pretty nasty, as to be expected. It cleaned up pretty well with only minor pitting at the outer most edge of the piston. It will not make contact with the seal so I am fine there. Everything else just cleaned and reassembled. Just need to order a stainless braided brake line. I need to measure it out, but thinking around 35" or 90cm should be fine on my tracker bars.

I also have intentions of putting some more aggressive tires on soon. I am leaning to a set of Shinko sr241. This is a more tracker / knobbie style tire and will have a bit more profile. To accommodate, I want to raise the fender a tad bit. I rough cut some steel adapter brackets to raise the fender up about an inch. I am working on obtaining an earlier style flat fender from a 75-76 model, as I think it will fit the theme better. I will need to figure out something with the fender stays though, or eliminate them all together. This is still up in the air though, and am just playing around with some looks. And yes I am aware the fender below is mounted backwards....
 
My Tru Value has a large selection of Nuts, Bolts, Washers, Bushings. Maybe they have a thrust washer close enough to rework.
 
Looking good there Rob, your usual meticulous work! ;)

While you’re in the starter, you can shine up the brush contacts on the armature and there is a multi meter test for the armature as well, I’m pretty sure it’s in the repair manual. Even though I don’t think they ever fail.
 
I don't know how big the thrust bearing is. My local True Value selection.
 

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I’m a bit of a parts collector. Always looking for good deals on things I think I can use. This week I picked up a VR115 regulator on eBay for about $20. I’ve been wanting to do this mod for a while and jumped on the deal. It’s a pretty simple project with the guidance of Jim and 5Twins write up
https://www.xs650.com/threads/diy-reg-rec-5twins-and-jim.55842/
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I tried a couple different variations of adapter plates. It was pretty simple with some thin gauge metal from my scrap bin.
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I cut the old wiring off and soldered it onto the VR115 wires. I made it a little long to give me some wiggle room. Added some wiring sheath and heat shrink and Banda-bing. I’ll still trim the plate up a little and I still need to test fit with the side cover, but I’m pretty happy with it. Next up is an updated rectifier.
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Unfortunately, I think the way you've mounted the VR115, it will hit the side cover. I think you'll need to rotate it 90° .....

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As usual, 5T is correct. New revised bracket solved the interference issue. But I did not like how much movement the bracket had with just two isolators, so I added a third and attached with a carriage bolt.
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Been a busy few days. I’ve been very productive in the shop while the family is out of town. My main focus and goal is to get the motor together and in the frame. Even though I suffer from serious mission creep, I still got a lot done. Started off yesterday afternoon installing a new set of Koni 7610 shocks. I’ve been watching for a set a while now, but prices have been holding high. Finally snagged a set reasonably. Bottom eyelets were correct size with a sleeve. Top mounts would not come out, so I just drilled them out to 14mm. Bottom swingarm mounts needed a little realignment but was able to persuade with a BFH.

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Also got a new headlight ring from fellow member Bosco. Not done with it yet, but I like it.
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Also cleaned up the shop. Was is dire need in order to assemble this motor. This morning I was all set to assemble. All went pretty well. A few hiccups and a minor struggle with riveting the new cam chain but I prevailed. Also cleaned the clutch cover and stripped the clear coat. Gave it a matching brush finish with the scotch bright. This motor has some nice goodies. 750 BBK. Elephant foot adjusters, single breather. I picked up the sweet exhaust from fellow member Halfmile. Phil made this beautiful high pipe setup with snuff-r-nots. I jumped on them when he listed in the classifieds. Phil makes some top notch parts, as you’ve seen in many of his builds.
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I also replaced the clutch pushrod seal and converted to single piece long rod. Pulled the front sprocket for cleaning and inspection. Was a little surprised to see the sprocket is a 16tooth. Not really heard of people running those. I found a new replacement sprocket nut and washer in the parts stash, so added those too.

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Hope to get this motor in the frame tomorrow. After that, next up is the front brake and wiring harness. We’ll see how far I get. There’s a swap meet in the next town over tomorrow. Gonna check it out and hope it’s not all HD stuff. But it’s been a while since I’ve been to one, so looking forward to it.
 
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well the swap meet wasn’t a total bust. As suspected it was just about all HD stuff. One guy had a few Japanese bikes for sale. An SR500, Xt500, and a cb650 nighthawk. The 500’s were very clean with asking prices about 4K. But just before I was about to leave I spotted an xs seat on the ground behind him. He didn’t know what it was off. I chatted with him a bit and bought the seat for $20. I needed a new foam for the one I butchered last summer. Made the trip worth it.
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And after disassembly and putting on my restored pan. I had an old cover for a different year, but I made it work. It’s not perfect, but for $20 I’m happy with it.
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