77 GET's HER 2008 MAKEOVER





As she was when she first arrived

  With a somewhat depleted Museum and workshop it is time to give the 77 TY Yam her 2008
makeover. I have been meaning to fit the "back and down" Miller footrests and also the WES Pipe.
So this last weekend it was time to wheel her out of her prestigious corner slot and see the light
of day again. 



A double win at Perris 2005

 The last time she had a major outing was 2005 when she won the very wet Perris double header
and we sank up to the axels in the mud in the RV!! I think her last ride was Diamond Don's when
I was as sick as a Parrot and could hardly walk 10 paces without having to take a rest.



Diamond Don's 2005

 So the plan is the new footers, new pipe and convert a TY175 seat, which I had professionally
recovered in purple before I discovered it is smaller than the TY250 in length and therefore won't
fit on the standard hangers. Nothing a little alloy bracket can't fix and when in situ looks a lot
neater.



Let battle commence!

 First up off with the old seat, chrome pipery and the old flat wide footrests. Now time for the
Makita as you must cut the old hangers off flush with the frame. This frame being a 77 has the
studded lower frame rail whereas some of the "434" frames do not unless you are lucky enough to
get a "CAT" model which had the forward rests and that long brake pedal. If you have a non
studded frame then use one long threaded bolt all the way through and put a self locker at each
end. Other things, if you are planning this yourself make sure your swinging arm bolt is long
enough, yes they come in different lengths, as the brackets are quite thick.




Removing the old footrest hangers



Makita, Makita !



Yes, they will fit

 Unless you want to take the entire back end of the bike to bits the best way to go is use another
SA bolt or front wheel spindle and tap the old out and then hold the package together while you
either clean the old one or fit the new. Some of the older bolts unfortunately do seize solid in the
bushings so if it won't come out easily sometimes drastic measures have to be taken! ..... and I
have resorted to the Saw! The bushings can also swell and are better than locktite and no amount
of force will shift them.

 The new exhaust system doesn't have a flange mount with it??? How annoying and I don't really
want to chop the old one in two as its in very good shape. Also annoying is the fact I threw a
beaten up system in the trash not so long ago and now I'm minus that flange. I think I will cut the
frame ends off and just go for a brace under the alloy mudguard which will also strengthen it a bit.
Everything else looks good on the bike so unless I do a strip down and respray (which I might)
this should be a quick (Ho, Ho) job.


 The respray and color change is becoming more appealing, might do the frame pearl silver, purple
barrel, purple cables, a lot of repolishing, I think the final "mind's eye" picture looks good. It is
after all a really nice bike and I would like to ride it more so this might be the way to go. 

 2 days with the power tools and a conveniently found piece of 1/4 inch steel and after drilling
round a series of little circumference holes the middle falls out and the filing begins! Then out with
the Makita and shape the outside, beginning to feel like a bronze age hunter crafting things out
of flint but eventually I'm getting close despite the workshop looking like a coal mine with metal
filings and Makita dust everywhere. The respray job is looking more and more like a go ahead
although Madam is asking why?

 Well as I can rebuild a Yam in about 3 hours from scratch, and Sunday is not an "Ebay" day, let
battle commence. Might even get round to fitting those main bearings in the TY175 then she can
go on the "For Sale" list. So if any of you are out there and have any old scrap trials bikes DO LET
ME KNOW!



Today its Silver Blue

 It got the total respray make over. Rapid dissassembly and I'm spraying before noon. Now while
the frame is drying in 112, I'll take the head and barrel off and give the barrel the purple treatment.
Then it will be cable time and just a little patience before the rebuild. Should have her finished by
Wednesday. Just spent a little time repolishing the brake hubs. These being Magnesium they look
fantastic when clean but they oxidize very quickly and in retrospect I wouldn't do it again.



Hubs polished and ready

 Another day and thanks to running backwards and forwards to MVD nothing on the bike front
accomplished other than to spray the barrel and about 30 mins cutting back the fins. Just need to
finish off with a fine grit and it will look better than a Harley.

 

The Barrel in Purple


 Very pretty and now it is Wednesday so time to bolt up the motor again and get as much done as
I can before we have to move on with our other plans and set off for Dolores again at 0600
tomorrow. Crack of dawn and I'm in the relative cool working on phase 1. Motor done, now in with
the ballbearings, 19 on the bottom, 22 on the top and the yokes are in. Next up the rear brake
pedal which unless you fit at this stage is a real bu%%## to get in.


 The swinging arm goes in along with the new "footers" and finally the shocks. Now, with the
engine on the floor just side manoeuvre the frame round it and "hey presto" the engine is in and
the bolts are all lined up. Bash plate on and now I can lift the whole package up on the stand.



Rebuild phase 1

 Handlebars, and front end all completed at this stage I at least have stability and I can quickly
tidy up on some of the smaller items. Chain guard and tensioner, and swing over for the brake
cable and sidestand. Last bit for the morning is the coil and that will be enough for 2 hours work.



2 hours later



 Now with most of the easy reconstruction done time time to redo the ignition, clean the carb and
replace all tubing with magic purple. Next, time to use the reformed old splash guard and reshape
the alloy fender and mount it over the old Ty250A fender brace as I have sawn off the rear frame
loop and neatly finished the tubes with blanks from ACE hardware.



The heart of the Purple People Eater

 Back wheel in and chain back on and now time to see how the new WES pipe will work out.
Standard piece of radiator hose and a couple of clamps. My new flange mount works and for a
first time "Billet" job I'm quite pleased with the result. Now reshape a brake anchor stay and that
will hold the tailpipe in place. The kicker now rubs the new Pipe so move it forward about 10
degrees and another problem resolved.



All my own work! the billet flange



The TY175 seat finally secured

 At this point time to work out how to fit the purple recovered TY175 seat which I'm determined
to use. Well its about 3 inches shorter and although it will go over the frame rails I have to
remove all the mounting brackets and refabricate my own. It's 1800 and the job is done and I'm
pleased. The nightime photography tends to make the frame a bluer color than it really is but
overall the colors seem to go together well. You of course might not like it? 



1800, and I'm done !



The new WES pipe



Ready for action



Neat and slim and the Yams nice too




Tony Down     with another BLACKCAT makeover