Getting a 200A going again.

These posts document restoration experiences of our members
RobertM
Posts:31
Joined:Sun Nov 14, 2021 9:00 am
Re: Getting a 200A going again.

Post by RobertM » Tue Nov 30, 2021 9:10 pm

-
Attachments
I08dn7J.jpg
I08dn7J.jpg (29.7KiB)Viewed 2265 times
SNv3HE5.jpg
SNv3HE5.jpg (39.64KiB)Viewed 2265 times

RobertM
Posts:31
Joined:Sun Nov 14, 2021 9:00 am

Re: Getting a 200A going again.

Post by RobertM » Fri Dec 03, 2021 7:23 pm

Made a few more pieces to the puzzle. Rebuilt the engine bolt brackets from stainless. Little bit each day.
Attachments
D2MNBII.jpg
D2MNBII.jpg (18.49KiB)Viewed 2247 times
cHLJYSp.jpg
cHLJYSp.jpg (23.27KiB)Viewed 2247 times

User avatar
Go Go Diablo
Site Admin
Posts:1830
Joined:Fri Feb 22, 2008 12:47 am
Location:Sobieski, Wisconsin
Contact:

Re: Getting a 200A going again.

Post by Go Go Diablo » Fri Dec 03, 2021 8:11 pm

I like the idea you have about making the motor mounts out of bar stock with studs rather than trying to wrestle your arm under the chassis to tighten a nut or a bolt. When I did a 200, I did just the opposite and put the nuts downward. It worked really well.

Thank you for sharing all your cool ideas Robert!
DSC06745.JPG
DSC06745.JPG (138.56KiB)Viewed 2246 times
DSC06750.JPG
DSC06750.JPG (140.02KiB)Viewed 2246 times
Too many Diablos and parts to count.
Yamaha 600 SX

RobertM
Posts:31
Joined:Sun Nov 14, 2021 9:00 am

Re: Getting a 200A going again.

Post by RobertM » Sun Dec 05, 2021 10:37 pm

.
Attachments
4fIj50s.jpg
4fIj50s.jpg (22.32KiB)Viewed 2236 times
eo57dZB.jpg
eo57dZB.jpg (25.04KiB)Viewed 2236 times

RobertM
Posts:31
Joined:Sun Nov 14, 2021 9:00 am

Re: Getting a 200A going again.

Post by RobertM » Tue Feb 01, 2022 10:06 pm

Got all the parts sandblasted which took a couple of days to do.

Always like to do projects with my father. He went to college to learn paint and auto body way back when, so he said he would help with the paint.
Everything is in primer. There is some rust pitting that needs to be smoothed out before the final paint.
Attachments
DseWJoP.jpg
DseWJoP.jpg (18.23KiB)Viewed 2004 times
6YoNoM5.jpg
6YoNoM5.jpg (51.15KiB)Viewed 2004 times
LZCjcEn.jpg
LZCjcEn.jpg (40.52KiB)Viewed 2004 times
Last edited by RobertM on Wed Feb 02, 2022 12:11 am, edited 1 time in total.

RobertM
Posts:31
Joined:Sun Nov 14, 2021 9:00 am

Re: Getting a 200A going again.

Post by RobertM » Tue Feb 01, 2022 10:17 pm

Bruce mentioned that he's come across several cranks that have slipped becoming untrue, and if I'm going after more horsepower this might be a problem.

Wondering if it might be an unbalanced clutch causing the crank slippage I pulled the clutch off and made a bolt to hold it while being spun in a crank balancer to check balance.

It showed the clutch to be very balanced.
Attachments
48siVcH-2.jpg
48siVcH-2.jpg (25.33KiB)Viewed 2004 times
2WzpZ3H-2.jpg
2WzpZ3H-2.jpg (31.79KiB)Viewed 2004 times
Uc77KzJ-2.jpg
Uc77KzJ-2.jpg (27.03KiB)Viewed 2004 times
Last edited by RobertM on Wed Feb 02, 2022 12:06 am, edited 1 time in total.

RobertM
Posts:31
Joined:Sun Nov 14, 2021 9:00 am

Re: Getting a 200A going again.

Post by RobertM » Tue Feb 01, 2022 10:51 pm

Diving into it a little deeper the crank and piston looked to be run very little.

Checked the crank for straightness and it was within 1.5 thousandths which is in the zone.

The next step was to take the crank apart for inspection.
Attachments
EIg5oB5-2.jpg
EIg5oB5-2.jpg (40.98KiB)Viewed 2004 times
WL5JFhZ.jpg
WL5JFhZ.jpg (24.36KiB)Viewed 2004 times
HaRwfUv.jpg
HaRwfUv.jpg (19.63KiB)Viewed 2004 times
Last edited by RobertM on Wed Feb 02, 2022 12:07 am, edited 1 time in total.

RobertM
Posts:31
Joined:Sun Nov 14, 2021 9:00 am

Re: Getting a 200A going again.

Post by RobertM » Tue Feb 01, 2022 10:57 pm

After the crank was apart I noticed one of the connecting rod thrust washers showed major wear which means something's crooked.
Attachments
X8aXX4e-2.jpg
X8aXX4e-2.jpg (28.67KiB)Viewed 2004 times
Last edited by RobertM on Wed Feb 02, 2022 7:43 am, edited 1 time in total.

RobertM
Posts:31
Joined:Sun Nov 14, 2021 9:00 am

Re: Getting a 200A going again.

Post by RobertM » Tue Feb 01, 2022 11:12 pm

In the search to find out whats crooked I had to check the cases where the cylinder mounts to see if it was parallel to the crank.

I did this by making a round bar that fits into the crank bearing holes and then measuring both sides of the cases.

In the end the measurement was the same which means that surface is parallel to the crank.

I'm thinking the base on the cylinder was milled crooked. I haven't checked it just yet.
Attachments
RvfOqBK.jpg
RvfOqBK.jpg (34.54KiB)Viewed 2004 times
SmKtwrH.jpg
SmKtwrH.jpg (38.8KiB)Viewed 2004 times
mcShhwi.jpg
mcShhwi.jpg (32.17KiB)Viewed 2004 times

RobertM
Posts:31
Joined:Sun Nov 14, 2021 9:00 am

Re: Getting a 200A going again.

Post by RobertM » Tue Feb 01, 2022 11:23 pm

On the connecting rod I filed off extra metal then sanded it to remove weight and make it stronger. Cracks will most likely start where there is an imperfection like the bumps left behind after casting, so if you sand it down flat its harder for a crack to start.

In the end I removed 15 grams.
Attachments
O7UAtri.jpg
O7UAtri.jpg (20.16KiB)Viewed 2004 times
17Mc44Z.jpg
17Mc44Z.jpg (17.9KiB)Viewed 2004 times
Last edited by RobertM on Wed Feb 02, 2022 12:14 am, edited 2 times in total.

Post Reply