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Project The Yamaha R4 (Glacially Slow Project)

Discussion in 'Other Projects - Other Bikes (non 250's)' started by maelstrom, Dec 20, 2014.

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  1. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    Is that an engine I see before me?
    [​IMG]
    [​IMG]

    [​IMG]
     
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    Last edited: Mar 20, 2022
    maelstrom, Mar 20, 2022
    #361
  2. Andych

    Andych Moderator Staff Member Premium Member Contributing Member Dirty Wheel Club

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    Looks a million $$. The Cerakote is such a nice finish.
     
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    Andych, Mar 20, 2022
    #362
  3. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    and now in stereo
     
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    maelstrom, Mar 20, 2022
    #363
  4. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    After an eternity, I sorted out all of the issues with 3D printing and machining the manifolds in nylon. That is what you see attached to the engine. Some of the details will be part of the next video. So if you own some sort of weird bike and have a manifold issue I might be able to help you out.
    ManifoldsFinished.jpg
    Cheers
    Blair
     
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    maelstrom, Apr 7, 2022
    #364
  5. Nate R

    Nate R Active Member

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    Former SRX250 owner, just got another!... And XT250, DR200 and R3
    Have you checked these for air tightness under vacuum? Just something to be aware of....I've seen 3D printed manifolds that sucked air THROUGH the material (gaps between)......
     
    Nate R, Apr 7, 2022
    #365
  6. inchoate

    inchoate Well-Known Member

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    yup, FDM printing is very porous.
     
    inchoate, Apr 8, 2022
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  7. jmw76

    jmw76 Well-Known Member

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    It depends a lot on how well you have your 3d printer set up. From my own experience, nylon is bugger of a material to print. Dimensional stability is a real issue.
     
    jmw76, Apr 8, 2022
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  8. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    Yes, you guys are right on those points. I did check them for porosity and I am aware of the dimensional stablity issue. Polymaker CoPA, after going through 5 rolls of the stuff, is solving all of my issues and I can print solid with it.
     
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    Last edited: Apr 8, 2022
    maelstrom, Apr 8, 2022
    #368
  9. jmw76

    jmw76 Well-Known Member

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    Polymaker CoPA. I will have to look into that. More recently I have had success with PETG.
     
    jmw76, Apr 8, 2022
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  10. jmw76

    jmw76 Well-Known Member

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    So Blair, looking at your manifolds, it looks like you have machined the head mating face and the o"ring groove. Is that correct?
    That would solve the potential bridging issue for the groove and ensure you have a good mating surface.
    Peter.
     
    jmw76, Apr 8, 2022
    #370
  11. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    Yes, that is correct. All in my next video.
     
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    Last edited: Apr 8, 2022
    maelstrom, Apr 8, 2022
    #371
  12. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    E10 Aaaargh where is the vomit emoticon?
    @Linkin mentioned this the other day, when bike is parked on sidestand the E10 corrodes away your carbs because it is hygroscopic and attracts water. Why do we have E10? So that politicians can be seen to be doing something. By the way, it was not me that did this.
    E10_01.jpg
     
    Last edited: Apr 15, 2022
    maelstrom, Apr 12, 2022
    #372
  13. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    You know the drill Mr. Green :) Threebond Engine Conditioner, small strands of wire, new bits where appropriate and a delicate hand :D
     
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    Linkin, Apr 12, 2022
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  14. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    So while cranking over my engine to get oil to the top end, one of these small rubber plugs shot out. Turns out it is completely loose. As Spock would say, fascinating. There are 12 of these and they would be a likely candidate for a loss of oil pressure. Note that the same is used on the 250 and yes, I know that they are retained by the cam cover (at least when new).
    I ordered a set of new ones and a few spare for medical experiments.
    CamCaps_01.jpg
     
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    maelstrom, Apr 15, 2022
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  15. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    Here is Episode 43 in which you get to see porous and non-porous 3D printed inlet manifolds. Gee, only took me about a year to solve all the issues.
     
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    maelstrom, May 15, 2022
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  16. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    Like sands through the hourglass ...

    Got some M6 Fuji nuts, exciting.
    M6_Fuji small.jpg

    FujiNutsFitted_01 small.jpg

    I got them from Saima in Japan. They sell real metric fasteners.
     
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    maelstrom, Jun 4, 2022
    #376
  17. ruckusman

    ruckusman White Mans Magic Master Premium Member Dirty Wheel Club

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    Blair,

    Huge thank you for this diagram - I was about to ask you to take some suspension linkage measurements, but of course you being you had already done it to perfection+

    Here's the image inverted on a white background for printing. DimensionsRearSuspension.png
     
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    ruckusman, Jun 6, 2022
    #377
  18. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    There is a bit of a delay happening in the project bikes department
    Clearing_03.jpg
     
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    maelstrom, Aug 25, 2022
    #378
  19. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    That will be a good size workshop/garage .... but wheres your house going ? :confused::cool::D
     
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    GreyImport, Aug 25, 2022
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  20. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    Speaking of where is the house going.
    Painting_01.jpg

    My poor shed remains in the future, somewhere.
     
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    maelstrom, Mar 26, 2023
    #380
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