Build thread and some thoughts on progress

[PineyPower]

Welp, been poking around here for about a year already I guess it's time to do the obligatory build thread.
It's been coming together in phases, and over a long period of time. I'm now about to enter a pretty substantial bit of matinence and upgrades so I wanted to take a moment to reflect...
How it started
Vs how it sits bow
Started simple with grips, modified pegs, a direct shifter, tires, and some matinence. Then I went with the cosmetics, reupholstered the seat, painted the frame, wrapped the rear fender and upgraded the headlights.
Eventually added an oil cooler, better handlebars, and the rear linkage from drw. I was running a banshee rear shock that unfortunately blew after a few rides.
Every step of the way I rode this thing, improving my ability, improving the machine, improving my ability, etc. It's been a process thats been evolving over the past year and a half.
The next big step is incoming though... Ive been slowly collecting parts for months now...I got my banshee shock back rebuilt and custom valved.I picked up a good second hand set of elkas for an early model 450. I've got a arms on the way that will work with them. New wide axle, dual piston calipers and stainless lines all around, fresh rotors and most importantly... more basic matinence. A year an a half of straight abuse on a 20+ year old machine will shake and break all the weak links out.
The plan is to make sure the chassis is fully sorted out then squirrel away engine parts and put it under the knife again this winter and have something well sorted, well balanced, and built right to last.
The whole point is... builds on toys dont happen all at once. It's a process you take as it comes. Most of the time you aren't doing anything that feels like it's worth bragging about especially seeing sone of the crazy builds on here but if you are keeping an old machine going trust me, the work is worth being proud of and sharing. And if the work I'm putting in happens to inspire somebody else than it was worth making this big ass post!
I'll be putting up some progress updates on what I've got going on the next couple weeks and in the meantime, if anyone has any questions feel free to ask. I've got alot of pictures of the mods and repairs as I've done them that I can share

 

[PineyPower]

The teardown on the rear half has begun. My swingarm bearings were a little out of spec so I decided it best just replace them.
The rear axle and hub splines are all wallered out and won't hold tight, the rear brakes mildly exploded, chain and sprockets worn out, and the whole shebang could use a good clean up.
Got everything cleaned up, painted, and parts laid out and ready for reassembly

 

[beastlywarrior228]

Looks good. Just keep tinkering with it.

 

[PineyPower]

Sadly ran out of time past this point but that's how things go. I'm not in a crazy rush, my a arms are still probably 2 weeks out and I've got some other matinence things to do so I'm taking my time with it. Everything that's supposed to move has grease, everything that's not supposed to move has lock tight and every bolt is getting marked so I can do a visual check after my next ride

 

[PineyPower]

It's back on all four wheels till the front stuff comes in. The suspension is buttery smooth and my rear brakes actually stop. This niche axle is weird with the clips, the big nut side especially but so far so good.
Next step is to tinker with the clutch again and if I have time this week do the valve stem seals

 

[YamahaNutz]

Don't forget to recheck the jam juts after a bit of riding. You'd hate to see it wear those new parts because it potentially settled and loosened up. I super cleaned my axle, replaced bearings, and had to re-torque those nuts(with clean threads and red loctite). The loose nuts is why those spline hubs wear.

What front arms are you going with?

 

[PineyPower]

Yeah the hub nuts being rode loose before I got the quad is one of the reasons i replaced the axle and hubs. The splines were just hammered. I've got every bolt I've touched paint marked for exactly that reason, easy to recheck. The axle is a niche adjustable one (same as the tusk/gforce) with the locking jam nut and though the weird clip set up has me wary after a brief shakedown nothing has moved.
Once they come in I'm going to be running full flights redesigned +2 arms. Apparently where they put the lower shock mount is technically wrong but makes early yfz450 shocks fit well

 

[YamahaNutz]

Or the shock location is done on purpose to run the better longer shocks.

I'm looking at running that axle shaft on mine

 

[PineyPower]

So alot of the front end stuff was covered in another thread, but for the sake of consolidating a bit...
The a arms are on and all adjusted up (this wasn't easy)
The front shocks are back from the builder, I need to fabricate upper shock mounts because a: I bought the wrong shocks and b: full flight fixed their design and c: I bought the wrong shocks even if they didn't
In the mean time I have the stockers on there while I try desperately to break in all the new ball joints and tie rod ends. Also:
Did bigger brakes and stainless lines up front too. Honestly that has been one of the most satisfying dollar to performance differences yet. Brakes grab a but harder and don't fade like they used to.
Progress is freakin slow, but hopefully the next couple weeks I can make the time to mount up the shocks. If I time it right, I'll be fully dialed in, broken, and fixed again by the time the east coast warrior meet up happens

 

[PineyPower]

The next couple of weeks, as it turns out, did not allow me the time to make the shock mounts.
It's okay though, my motor decided today that it wants to get upgraded. It hasn't wanted to start the last couple nice weekends we had and it turns out it jumped timing. I had just started squirreling away some motor upgrades but this is expiditing things. Lol, there's a whoooole lot of "well while I'm in there" going on that gonna cost me a paycheck but it is what it is.
Going with a je 10.5-1 85mm piston (366) a web 4.27 cam, kibblewhite black valves and springs w/titanium retainers, a mild Port on the head and feeding the whole thing with a keihin 39mm fcr carb. It's the little things, like the timing chain, gaskets, adapters and bearings that take time to find good and priced right but I got it where I only have to send the cam and jug out and im good to go. Research and price shopping time is not to be underestimated!

 

[YamahaNutz]

The dual piston calipers and pads is literally a night and day difference. It is so much smoother and controllable.

Sucks it not running, but that just makes the excuse to upgrade!

 

[The_Mistress $$$]

Welp, been poking around here for about a year already I guess it's time to do the obligatory build thread.
It's been coming together in phases, and over a long period of time. I'm now about to enter a pretty substantial bit of matinence and upgrades so I wanted to take a moment to reflect...
How it startedView attachment 5535
Vs how it sits bowView attachment 5536
Started simple with grips, modified pegs, a direct shifter, tires, and some matinence. Then I went with the cosmetics, reupholstered the seat, painted the frame, wrapped the rear fender and upgraded the headlights.
Eventually added an oil cooler, better handlebars, and the rear linkage from drw. I was running a banshee rear shock that unfortunately blew after a few rides.
Every step of the way I rode this thing, improving my ability, improving the machine, improving my ability, etc. It's been a process thats been evolving over the past year and a half.
The next big step is incoming though... Ive been slowly collecting parts for months now...I got my banshee shock back rebuilt and custom valved.I picked up a good second hand set of elkas for an early model 450. I've got a arms on the way that will work with them. New wide axle, dual piston calipers and stainless lines all around, fresh rotors and most importantly... more basic matinence. A year an a half of straight abuse on a 20+ year old machine will shake and break all the weak links out.
The plan is to make sure the chassis is fully sorted out then squirrel away engine parts and put it under the knife again this winter and have something well sorted, well balanced, and built right to last.
The whole point is... builds on toys dont happen all at once. It's a process you take as it comes. Most of the time you aren't doing anything that feels like it's worth bragging about especially seeing sone of the crazy builds on here but if you are keeping an old machine going trust me, the work is worth being proud of and sharing. And if the work I'm putting in happens to inspire somebody else than it was worth making this big ass post!
I'll be putting up some progress updates on what I've got going on the next couple weeks and in the meantime, if anyone has any questions feel free to ask. I've got alot of pictures of the mods and repairs as I've done them that I can shareView attachment 5537

I would throw white on that teal frame I love the white and teal color together

 

[PineyPower]

I'm a diesel mechanic, that white wouldn't stay white for long lol. The plan was to do some accents in either pink or purple... go for that late 90's starter jacket or Miami at night vibe but I never got around to doing more of the graphics. The vynal wrap I did on the rear fenders gotta get redone before I go decaling over it but that all will probably be the final step in the build

 

[PineyPower]

Playing some head games of my own. Its my first rodeo but i did alit of research before diving into this to avoid mistakes, feel like I got it about as good as it gets without special tooling or years of experience. Some before and afters (I still want to do a final pass with something like 220 but the shape is there)
Intake side I skinnied up the valve guide, shaped a fin to the stock contour of the guide boss and pulled a little material out of the sides to widen the port a bit around the guide. The wall angle let me clean up a nasty edge in the casting that would snag the air right where it typically flows the most. There's also a part not pictured in the floor that they machine straight through for the valve seat, completely defeats the purpose of raising the floor and making the bend more gentle. I did some reshaping there and left the overall height of the bump in the floor the same. I didn't touch the valve seat or the guide itself, as that's getting where you need a machine shop and special equipment.
The exhaust side got a similar treatment, but I took a little more out of the floor on this side and worked the guide a little different. The exhaust port shoots off at an angle so rather than fight the asymmetry I focused on flow. Gotta help the air go where it wants to, not force it around.
Next step is to work the shrouds a little and mabey a bit more bowl work while I polish

 

[YamahaNutz]

Looks decent. About what I did on my current head except not touching the intake floor(my mistake). If you haven't done it yet, I'd bolt the intake adapter your using on so you can mark and blend it.

I know exactly what you mean with the intake valve seat machining making a pocket-like ridge on the outside of the port's radius. It's as if they were sloppy in the casting and let the intake port mold go too deep in the head. My '87 head was opposite with the ridge on the floor side. Maybe it is just a worn casting mold thing. The '93 head I have isn't bad, but my '07 raptor head is much worse.

 

[beastlywarrior228]

Looking good

 

[PineyPower]

"It's as if they were sloppy in the casting and let the intake port mold go too deep in the head"
Now that I think of it yeah, that's exactly it. Same on the exhaust side too but it's not as obvious.
I should be getting my jug and cam next week... if I'm real good and lucky I could have it running next weekend, but odds are other life obligations will get in the way lol

 

[PineyPower]

Also done shaped up the combustion chamber a hit. Goal was to de-shroud the valves a bit and just generally clean up the casting. Pulling material away from the plug side of the intake should help the air swirl into the plug and pulling the shroud away from the exhaust should help port flow during the low lift parts of the camshaft cycle.
Sure it isn't perfect but I'm willing to bet it's better.
Also got my fcr all cleaned and rebuilt, with a half price boysen quick shot 3 installed and ready to drive me nuts tuning
With any luck this week I'll get my jug and cam and in a perfect world I'd be able to put it all together and install it and ride it this weekend!
World ain't perfect though, if I'm lucky it'll be ready for the 23rd

 

[YamahaNutz]

Looks good! Don't forget to have a few extra spark plugs on hand for tuning.

 

[beastlywarrior228]

That's fine to clean up the combustion chamber but just know you're taking away compression even by playing with the chamber volume a little bit.