1967 Yamaha DS-5 250cc Rebuild

Thank guys. The chrome work lets it down a bit (doesn't show in photos) but rest is 'spiffy'. Keen to get the last bits so can start and ride it.

 

I filled the gear box with oil a few days ago and this morning found a puddle under the engine. Whilst looking with torch I discovered that the gasket under the selector cover is leaking. It was the only gasket I didn't have and thought I could get away with just some sealer on it. Well it didn't seal and now will have to drain gearbox and make a new gasket for it.
"Do it right the first time or it will come back to bite you", and it has.

 

So today I layed it on its side and took the cover off. Made a new gasket from sheet, wipe of sealer and fitted with new screws. No leaks now.

 

Bought a new battery yesterday, the fuel tap arrived today, fitted with new hoses and clips, so with a litre of premix that I drained from the Maico I gave the button a push and she spluttered into life. Yes, it lives! I ran the bit of premix to make sure it had some lube until all the air bubbles were out of the oil pump lines. Clutch works fine and selects all gears. Bonus!
Too sore to ride today so just filled the shed full of smoke running engine. Starts easy off kickstarter too.
The left head gasket leaked a little, so off with head and rubbed on glass with sandpaper, good clean and back on. No leaking now. Earth for left rear blinker needed a bit of fiddling but working now.
Only thing missing now is the tank badges. Hope to have them before the show.

 

Today I took it for a 'street test'. It has been almost 18 months since I dragged it home, a worn out and broken down wreck. As found at scrapyard.

A few things need some adjustment, it's a bit 'boggy' off idle but runs clean and pulls well once past 2,000 rpm. Clutch drags a bit and cable adjustment had that sorted. Brakes are 'nothing to write home about' yet, but being new linings I expect they will get better as they bed in. The front suspension is good, but the back is a bit stiff even on the softest setting, something to get used to. Gear change need a definite stab to change, not quite the 'hot knife through butter' like the Honda's. Right carb dribbles when stopped, and floods into the cylinder. Think I will need some new needle and seats.
Overall pleased with its first run.




Note the lack of a rear vision mirror. Had two that I had ordered from China arrived last week, both bent and glass broken. Now have to sort that little problem with ebay/post office.