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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. ruckusman

    ruckusman White Mans Magic Master Premium Member Dirty Wheel Club

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    I like all of the rest because it was for legitimate purpose, Nik's manufacture and fabrication is magnificent and the attention to detail is merited - that just looked like a lot of doin' it the hardest way - Richard's still got a full head of hair but yeah I think you're right, Nik's challenging his endurance...
     
  2. maelstrom

    maelstrom LiteTek Premium Member 250cc Vendor Contributing Member

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    Yamaha FZR400 3TJ1, Honda MC22
    Airbox
    Finally got the airbox adapter merged with the velocity stack. Printing all 4 as part of the baseplate will be the next headache.
    I made the lip rounder than the Keihin part.
    Airbox_Base_02 small.jpg

    Airbox_Base_01 small.jpg
    If you can imagine the baseplate sitting on top of those air jet vents then you will get the idea. The baseplate also needs to incorporate those carb vents and the crankcase breather.
     
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    Last edited: Nov 8, 2024
  3. maelstrom

    maelstrom LiteTek Premium Member 250cc Vendor Contributing Member

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    Drip, drip:
    Lengthened the sidestand by 40mm. Have to shorten or remove the kicklever thingy and the mount needs to be built up with weld because the sidestand retracts too far, almost hits the swingarm.
    Sidestand_007_Small.jpg Airbox_Base_03_Small.jpg

    the mounting of the airbox base is going to be a little tricky. I might be able to get away with studs but access to the nuts does not look so good. Time for some more thinking.
     
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  4. maelstrom

    maelstrom LiteTek Premium Member 250cc Vendor Contributing Member

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    Clutch Lever Assembly - Part 2
    Nah, previous idea is rubbish. Not as rubbish as the Chinese thing, or the OEM thing, but still rubbish, so we need to make a pivot. Now I know you blokes think that I call everything rubbish, and that is true because everything is rubbish. Well nearly everything, Bimotas don't have much that you can call rubbish. Back to the story, there are actually four of these to deal with; they are the hand and foot control pivot points. The foot controls are going to be a big job because they are total crap, as are “rearsets” that people sell, vomit. Anyway, as part of this fix I am using a shoulder bolt, not a very good name as they don't actually clamp.
    Bolts_002_Small.jpg Machine_001_small.jpg

    On the left is a standard shoulder bolt and on the right I machined the head down to suit this application. Now the mount needs to be bored to the same diameter as the head. You cannot fit it like a normal fastener.

    Done_1 _Small.jpg Done_0_Small.jpg
    Done, now onto the lever.

    So I bought some of these to play with. They are self-lubricating bushes.
    bushing_small.jpg . Lever_004_small.jpg
    The shaft size of the bolt is 8mm nominal. Allowing for our self-lubricating bush, means we have to bore the lever out to 12mm. These bushes are already snug on the inside, so rather than risking too much crush, I just drilled the lever out to 12mm and fitted with epoxy.

    BoltFinal_02_small.jpg Finished_small.jpg
    Then I decided to machine the top of the bolt flush. The shaft has been hardchromed and the rest of it is nickel plated (plating cost $9.26 AUD). Of course I greased it on assembly.
    It is smooth as silk and has zero play. Happy :)
     
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    Last edited: Dec 18, 2024
  5. maelstrom

    maelstrom LiteTek Premium Member 250cc Vendor Contributing Member

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    Meanwhile at the airbox - more layers:
    The first layer is now carb to airbox. Everything is a tight fit here, so lots of failed versions went into the scrap heap. Eventually got something that fits, so now I need to print 4 of these in nylon, machine some o-ring grooves into them and fit M5 studs. Then it will be back to the baseplate layer.
    Airbox_Level-1 small.jpg
     
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