3XV Big Off rebuild

[ybk]

I'm also quite pleased with my ultrasonic cleaner - some solution + the heater and it becomes a very effective parts washer! I'm putting anything that will fit in there 

Good luck with the bleeding! Looking at the manual you'll probably need the stars to align as well

[Paul]

Nice when a plan comes together
If you're not careful summer will be over so get it running, ride it and further your strict requirements in winter.. YOLO my kids say.

[stevewr250]

Haha I think your the oldest person in the world to use that phrase Paul

[Paul]

BA Barakas was older than me!
Okay but it's never too late to realize you only live once

[yanw]

With Paul's chiding still fresh in my ears I went out to do a bit on the bike today. I kinda wish I hadn't.

Firstly, star of the week is Dan Maccas, thanks Dan (twice).

Today's task was to set the powervalves. I put the battery on charge and removed the left/upper exhaust. Armed with Dan's instructions on setting powervalves (*) I put the battery on the bike only to realise it's just a bit shagged. No lights on the bike and only 6V after an hour on charge, so I put it back on (up to 9V now...). No worries I thought, I will dry fit the new exhausts like Dan told me to (**).

I had a look up into the cylinder and noticed there was a couple of very light scores in the barrel on the carb side. Bugger. Next I tried the flange and the studs don't line up  . The headers I have (that I spent the time getting O-rings for) have symmetrical holes across the diameter of the exhaust and the R/RS ones are offset and by the looks of it at different distance from the exhaust. I removed the studs and checked that the exhaust fitted and by the looks of it it does.

Next I moved onto the right/lower cylinder. One of the stud nuts wouldn't come off and rounded so I spent the next hour with the PluGas, Clarke rotary tool and a punch & hammer. While taking a breather I noticed some light rust spots on the right fork stanchion which must have been from gravel flicked up when I came off. Bollocks. I cleaned it up with some Brasso and put some of that Scotoil corrosion inhibitor on it.

When I finally got the exhaust off I confirmed that the header was unsuitable for the other side ( I guessed that way). Undeterred I offered up the RHS exhaust only to discover that the hanger bracket is absolutely no where it needs to be, and is actually nearer the footrest bolt than the hanger. Tw*t.

Ready for the final kicking I had a look into the cylinder (the one that is feed from the oil line that was broken) and the piston was coated in 2T oil and the barrel surface was mint. (Slight) hurrah!

Before I tried the RHS exhaust I was considering getting the headers either modified or some new ones made up. Now I really don't know what to do. I'm looking forward to telling my wife I've spent £400 on not much more than a few old cat food tins. Dan told me that someone else was looking at those pipes when I got them (Gary?) and was miffed that they missed them. Count your lucky stars that it wasn't you.

Anywise, these were the pipes so if anyone has any suggestions please let me know http://pure2strokespirit.net/forums/index.php?topic=635.msg6641#msg6641. I'm kinda wishing I had written the bike off last year instead of looking to fix it.

I'm also very not happy with the guy who sold me the pipes as DFR 3XV pipes. It might have been an "honest mistake" but I've often heard the expression "make it someone else's problem".

[maccas]

Hmmm.

Can you measure the stud centres on both the flanges and the cylinder yan? Maybe the 3xv30 cylinders have a different spacing to 00 cylinders? Someone with 00 cylinders would have to confirm as i don't have one. Does seem very odd though.

I might be able to get some flanges made up for you if we canascertain exactly what it is we need? I could rapid prototype one out of plastic first to make sure it's correct.

Dan

[maccas]

I wonder if they are 3ma flanges. Not 3ma jackal flanges as they only have one spring loop but they could be off a different make 3ma pipe. I have a 3ma jackal flange in uni so can measure it tomorrow!

Dan

[ybk]

3xv00 cylinder stud spacing is 79mm( centre to centre of each stud), either the 3xv30 cylinders are different or the flanges are for some other model?

I understand the frustration, bought dfr pipes and stored them for a year, tried installing them and turned out I got sp pipes and flanges  was advertised incorrectly!

At least the flange exit is straight, should be easy to have some made (dfr ones are all angled which is a little more tricky to remake). Shame about the hangers though

[Warwick]

I can confirm that -00 and -30 cyls are the same.

Probs little comfort for you just now Jan, but your experiences here are not at all unusual I'd say. Modding is seldom as straightforward as it all looks once the job is finished. Keep at it. You'll work it all out eventually I'm sure .

[maccas]

Cheers Warwick. That eliminates that then.

Dan

[yanw]

Thanks for the assistance Dan and the sage advice Warwick.

I have made the measurements and they are below with a picture of the "Yamaha" exhaust manifold. I checked both heads and they are cast 3XV-50. I checked both barrels and they are cast 3XV-30. I checked the "Yamaha" pipes and they are stamped 3XV1-1 and 3XV1-2. I checked my glasses and my vernier callipers and they both looked straight. These puppies are neither in the plane of symmetry nor symetrical. Some of my measurements might not be bang on but not by that much.

3xv00 cylinder stud spacing is 79mm

The collars (and pipes, except for the RHS mount (maybe?)) might fit on a 3XV-00 cylinder then?1!?!

I'm off to check the parts book as this is more surreal than the Healing Field at the Glastenbury Festival.....

[stevewr250]

Keep at it Yanw we all have shit days but you will sort it just don't let it get to you.
Have a cupa and start at it again it will work out good luck

[yanw]

Keep at it Yanw we all have shit days but you will sort it just don't let it get to you.
Have a cupa and start at it again it will work out good luck

Thanks Steve, after what I have read and seen I'm thinking it's not me, it's Mr Yamaha...

Well, I checked the parts book and it shows the "Yamaha" pipes are the same item across the whole R/RS 91-94 range. It's odd as the "Yamaha" collars have to be on the pipes before they are welded. They didn't look like they had been off the bike and along with the crush gaskets there was lots of black silicon. Was that a factory fitment/sealant?

The headers definitely match the barrels and the barrels show no sign of reworking or drilling. (I'm getting tempted to JB Weld them up and get them re-drilled...)

Wullie has a 93RS, I wonder if he had issues with pipes?

[maccas]

I think it's just that the flanges you got with the jackal pipes are wrong for a 3xv. I reckon they are 3ma flanges yan. I'll measure a flange i have kicking about first thing tomorrow for you. The good news is that if they are for a 3ma then they are at least desirable so you should be able to sell them on fairly easily.

Does anyone have any detailed pictures of R model 3xv Jackal flanges?

Dan

[Warwick]

Can't really follow your post there, Yan? but you know the Yam flanges only fit one way round don't you?

As mentioned, -00 and -30 cyls are identical in terms of casting and exhaust fitment. Pipes that fit any R/RS will fit any other. 

Your set-up looks completely stock to me.

Yes, the black gasket goo is the oe Yam stuff. Don't know what it is, but it must be bloody good, because it seems very heat/oil resistant.