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Classic Bike Trackdays

Another SDR project
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thump566



Joined: 28 Jun 2023
Posts: 31
Location: West London

PostPosted: Thu Nov 16, 2023 6:27 pm    Post subject: Another SDR project Reply with quote

Six months ago I bought an SDR project with the intention of a sympathetic restore to be on the road for the following spring/summer.

It was sold as a non-runner and I was clearly told that it had seized. Its a single cylinder 2 stroke so assumed - head and barrel off, possible replacement piston/rings and a hone/rebore at worst. Unfortunately its turned out to be significantly more work than I anticipated.

I am intending to post images as the project progresses but cant currently see where to attach them?
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waggytee



Joined: 29 Nov 2022
Posts: 17
Location: Shopshire, UK

PostPosted: Sat Nov 18, 2023 9:45 am    Post subject: Reply with quote

Do projects ever turn out differently Very Happy

I struggled with embedding images also - I believe that you need to set up an image hosting site or dropbox, and then paste a link rather than just attaching a photo from your hard drive straight into the forum.

Guidance says that you're supposed to add the [img] at the start and end of the link and that should display it, however that never worked for me so I just inlcuded the raw link as per the below.

Hopefully see some photos of the 'before' shots and then the 'after' in the spring Wink

[img]https://www.dropbox.com/s/72zyhbinl7h5ooq/1.jpg?raw=1[/img]
https://www.dropbox.com/s/72zyhbinl7h5ooq/1.jpg?raw=1
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thump566



Joined: 28 Jun 2023
Posts: 31
Location: West London

PostPosted: Sun Nov 19, 2023 7:48 pm    Post subject: Reply with quote

Fortunately I took a few pictures prior to the initial enthusiastic 'dive straight in' strip down. Once I have mastered Dropbox I will post some of them.

A challenge is often great but its only a challenge if there is a chance of achieving the desired goal Rolling Eyes
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DSBBadmin
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Joined: 13 Nov 2006
Posts: 722

PostPosted: Mon Nov 20, 2023 4:24 pm    Post subject: Re: Another SDR project Reply with quote

thump566 wrote:
I am intending to post images as the project progresses but cant currently see where to attach them?

Yeah, you can't upload images directly to this site I'm afraid, they have to be stored online somewhere else already and then you can either provide a link or reference them using [img] tags and they'll be embedded in your post.
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thump566



Joined: 28 Jun 2023
Posts: 31
Location: West London

PostPosted: Mon Nov 20, 2023 6:31 pm    Post subject: Reply with quote

Will need to try and find a free hosting site.
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thump566



Joined: 28 Jun 2023
Posts: 31
Location: West London

PostPosted: Sat Jan 27, 2024 8:51 am    Post subject: Reply with quote

Hopefully this will work?

This was the SDR when I collect it last year prior to any work on it.

https://ibb.co/PxHdDd6

Please let me know if you can/cannot view the image ok before I add more.

Cheers.
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mikog
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Joined: 10 Jul 2008
Posts: 8
Location: West Yorkshire

PostPosted: Sat Jan 27, 2024 10:32 pm    Post subject: Reply with quote

Looks good to me.
It doesn`t look like it needs much doing to it.
I`ve always fancied a Whippet.
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thump566



Joined: 28 Jun 2023
Posts: 31
Location: West London

PostPosted: Sun Jan 28, 2024 8:36 pm    Post subject: Reply with quote

mikog wrote:
Looks good to me.
It doesn`t look like it needs much doing to it.
I`ve always fancied a Whippet.


The seller told me it was seized when I viewed it. I thought - small single cylinder stroker - probably hone the barrel, new piston and rings then away we go.

Unfortunately, after "easing" the barrel off I discovered a badly corroded crankshaft and about a pint of brown water beneath it.

https://i.ibb.co/vDRW2Ys/20230415-174643.jpg
https://i.ibb.co/FsVcXPt/20230628-200357.jpg
https://i.ibb.co/cLfWSJn/20230705-155200.jpg
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thump566



Joined: 28 Jun 2023
Posts: 31
Location: West London

PostPosted: Sun Jan 28, 2024 8:42 pm    Post subject: Reply with quote

The horror story pictures - I think the seller was a little economic with info regarding the seizure.

https://i.ibb.co/bdrPcKN/20230706-064755.jpg
https://i.ibb.co/ckX63tN/20230706-180740.jpg
https://i.ibb.co/1sk7JW5/20230726-173019.jpg
https://i.ibb.co/q1cPpbv/20230726-175752.jpg
https://i.ibb.co/B3HkJt4/20230830-165534.jpg

The crank is currently being checked, if it is not salvageable then it will need a new crank, fortunately they are still available from Yamaha but lets see what the prognosis returns first.
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mikog
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Joined: 10 Jul 2008
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Location: West Yorkshire

PostPosted: Mon Jan 29, 2024 10:24 pm    Post subject: Reply with quote

O dear, I see what you mean, it needs a bit more than a quick wire brushing.
It looks like the crank could possibly be salvageable to me.
Hope you get some good news soon.
On a more more positive note the rest of the bike looks very good.
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thump566



Joined: 28 Jun 2023
Posts: 31
Location: West London

PostPosted: Tue Jan 30, 2024 3:42 pm    Post subject: Reply with quote

One of many questions has arisen, namely ... is the SDR standard chassis Nickel or Chrome plated?

I have read articles with both being mentioned but dont know which is correct. Its appears to be lacquered with places being worn or chipped (the lacquer only) and I would like to sort those areas but not sure of the coating and how to rectify it?

If anyone has attempted attacking the chassis please let me know how it went.

Whilst the engine is away I hope to start on the chassis, replacing bearings where appropriate or possibly look at overhauling the suspension.

The hoses should be easy to source as I have a good contact in that field that provided a set for another jap import previously.

The list of items to be actioned is currently expanding on the whiteboard.
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James P



Joined: 31 Mar 2013
Posts: 185
Location: Sydney, Australia

PostPosted: Sat Feb 17, 2024 11:51 pm    Post subject: Reply with quote

thump566 wrote:
One of many questions has arisen, namely ... is the SDR standard chassis Nickel or Chrome plated?

I have read articles with both being mentioned but dont know which is correct. Its appears to be lacquered with places being worn or chipped (the lacquer only) and I would like to sort those areas but not sure of the coating and how to rectify it?

If anyone has attempted attacking the chassis please let me know how it went.



Ron,

Popular opinion suggests nickel plating, although I think that nickel is also used in the 'normal' process for decorative chrome plating.

The clear coating on my own SDR frame was brittle enough in some places to be scratched off using a fingernail, but was still very tough in other places - it seemed unaffected by prolonged coating with paint stripper. I elected to just clean up my frame as best I could and I repainted the hidden unpolished areas with silver POR-15 rust preventative paint (these areas had accumulated just a little surface rust).

I understand that there are powder and/or ceramic coatings available which mimic chrome quite well, so these may be an option if refinishing of the whole frame is preferred. Alternatively, a medium-to-brighter silver painted finish would unlikely look out of place if one isn't especially concerned with maintaining the original appearance.

Regards,
James
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thump566



Joined: 28 Jun 2023
Posts: 31
Location: West London

PostPosted: Wed Mar 06, 2024 9:26 pm    Post subject: Reply with quote

The crankshaft was salvageable fortunately, and the only concession was turning down one side of the shaft (rotor side) to address pitting. Fortunately it was then able to use the DT200 oil seal to match the machined shaft. The crankshaft has been rebuilt with a new conrod and small end bearing.

The cases have been vapour blasted to clear any corrosion and awaiting fitment of new bearings throughout.

The barrel and head were also cleaned, the barrel subject to a mild hone and supplied with a new Wossner piston and rings.

In the interim I have been cleaning up the trellis framework, it has amassed around 35 years of weather and taking a fair amount of TLC.

I will add a few more image inks when I get a chance.
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thump566



Joined: 28 Jun 2023
Posts: 31
Location: West London

PostPosted: Fri Apr 05, 2024 10:11 pm    Post subject: Reply with quote

While the cases were away being cleaned and the crank refurbished at PJME, I spent time cleaning the chassis - a much bigger job than I thought but hopefully will be worthwhile in the end.

Attached are a few images of the template I created for the crankcase bolts - luckily the template prints on an A4 page well and it practically the same size as the crankcase which was a fluke.

I was also planning to install a tacho as outlined in JamesP SDR rebuild but discovered the drive parts were now NLA. That went out of the window until I spotted an SDR parts bundle on eBay and snagged them for a Greek breaker . The bundle included the NLA parts and I have now ordered the other items from a UK Yamaha dealer plus finding an instrument panel in the UK of an SRX400 which has the OEM tacho to migrate across.

Also attached is an image of the reed valve stops - one before and one after cleaning. Another casualty of water ingress and not something as yet that I have identified the cause of but hopefully it will become clear as the rebuild continues.

https://ibb.co/SVLL5Hw
https://ibb.co/88dFfdw
https://ibb.co/8ry03w2
https://ibb.co/mCM3Whc
https://ibb.co/12LpmsV
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thump566



Joined: 28 Jun 2023
Posts: 31
Location: West London

PostPosted: Sat May 04, 2024 6:58 pm    Post subject: Reply with quote

Ok, the trellis frame is like a mini Forth Bridge, at least it feels like it whilst cleaning it up.

The refurb progress took a hit as I was away for 4 weeks although a bundle of bits was waiting on my return, hopefully the package contains all the items for the DT200R speedo drive mechanism plus the cable.

I have ordered a workshop stand to use whilst both front and rear end remain off the bike which will hopefully be useful as the re-assembly progresses. Yes I could have made my own stand but there is currently a long list of jobs and the stand would have been yet one more.

To be continued ...
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