model 600 restoration

These posts document restoration experiences of our members
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Go Go Diablo
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Re: model 600 restoration

Post by Go Go Diablo » Sun Jan 01, 2012 7:52 pm

You are a true craftsman my friend :D
Too many Diablos and parts to count.
Yamaha 600 SX

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Barrie2777
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Location:Arundel Quebec

Re: model 600 restoration

Post by Barrie2777 » Sun Jan 01, 2012 8:50 pm

It is the crafting of parts and how they can be made with such minimal tooling that I enjoy so much.

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fap67
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Re: model 600 restoration

Post by fap67 » Sun Jan 01, 2012 10:02 pm

Barrie2777 wrote:It is the crafting of parts and how they can be made with such minimal tooling that I enjoy so much.
Ditto

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Barrie2777
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Re: model 600 restoration

Post by Barrie2777 » Tue Jan 03, 2012 12:03 pm

All back together and ready for sandblasting.
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600 dash reinstalled 004.jpg
600 dash reinstalled 004.jpg (140.45KiB)Viewed 6183 times

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Barrie2777
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Re: model 600 restoration

Post by Barrie2777 » Mon Mar 26, 2012 8:43 pm

Back at it ...I held my breath and tackled the boggie wheels. Almost as bad as the Diablo boggie stations. These rubber wheels are sandwiched between two formed metal hubs which hold the bearings. One hub on each side and held together with 12 rivets of two different lengths. Each wheel is a tight fit on its shaft and held in place with a "C" clip.........and 50 years of rust.
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model 600 restore 003.jpg
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Barrie2777
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Re: model 600 restoration

Post by Barrie2777 » Mon Mar 26, 2012 8:49 pm

This boggies must have had its bearing changed. The owner opted for the bolt fasterers rather than the "clean" rivet method.
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model 600 restore 007.jpg
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Barrie2777
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Re: model 600 restoration

Post by Barrie2777 » Mon Mar 26, 2012 8:55 pm

There are two different thicknesses of boggie tires. The thick one takes two 6203 bearings while the others take only one. There are 6 single bearing boggies and two double bearing boggies.
Attachments
model 600 restore 015.jpg
two different thickness of boggie tire
model 600 restore 015.jpg (148.59KiB)Viewed 6119 times
600 base parts 001.jpg
boggie station components
600 base parts 001.jpg (140.02KiB)Viewed 6119 times
model 600 restore 009.jpg
boggie wheel frame
model 600 restore 009.jpg (131.89KiB)Viewed 6119 times

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Barrie2777
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Re: model 600 restoration

Post by Barrie2777 » Mon Mar 26, 2012 9:10 pm

An anvil made to conform to the inner shape of the hub was necessary to provide a solid surface to rivet against. It is also useful to hold the 6 short rivets in place when you turn the first hub over to assemble the other parts. Once all the short rivets were done , I inserted the long ones and secured them . This rivetting was done with an air hammer and a rivetting end identical to those used to rivet track cleats in place. This rivetting end had to be turned smaller at the tip so as to prevent damaging the hub whilst rivetting. OH what fun!!! Actually, it was about 5 minutes to assemble one boggie wheel. Several years ago I traded a Bombardier Olympique for two sets of NOS boggie tires for a 600 HUS-SKI. The hubs were powder coated.
Attachments
bling on 2 sets of boggie wheels.jpg
bling on 2 sets of boggie wheels.jpg (144.09KiB)Viewed 6119 times
anvils needed to rivet the boggies together.jpg
anvils needed to rivet the boggies together.jpg (141.49KiB)Viewed 6119 times
boggie wheels ready for rivetting.jpg
boggie wheels ready for rivetting.jpg (153.49KiB)Viewed 6119 times

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Barrie2777
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Re: model 600 restoration

Post by Barrie2777 » Tue Apr 03, 2012 4:28 pm

With the boggies assembled, I'm ready to prepare the track. The inner race of each bearing was heated to allow it to slide easier onto the shafts.
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600 boggie set assembled.jpg
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Barrie2777
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Re: model 600 restoration

Post by Barrie2777 » Tue Apr 03, 2012 4:34 pm

This track is made with 3/8" (maybe thicker) belting and must weigh near 100 lbs with the metal ice cleats. Turning this over the small front cog may take a lot of power in very cold weather.
Attachments
600 track ready to paint.jpg
600 track ready to paint.jpg (148.03KiB)Viewed 6097 times
600 track painted.jpg
600 track painted.jpg (150.63KiB)Viewed 6097 times
600 track pulled together.jpg
600 track pulled together.jpg (141.89KiB)Viewed 6097 times

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