Author Topic: RD200a & RD350  (Read 3340 times)

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Offline Foy(notFox)

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Re: RD200a & RD350
« Reply #60 on: February 28, 2019, 12:41:56 AM »
Yes Fredswat. In Japan their year is -25. like 45 = 1970. Anyway am interested that you and rsvr1000 both recommending PJME. I liked the look of their site and mentioned it on Facebook Aircooled page and everyone told me to use Grampian Motors.

Also surprised the cases came apart so easily. I thought the tool was a must and something to push the crank out the LH case too. Or at least to draw it back in on re-assembly. I actually cracked my AS3 LH case trying to tap them apart, per the Haynes manual  :(
« Last Edit: February 28, 2019, 12:53:32 AM by Foy(notFox) »
CS3B, AS3, RD125, RD250C, Honda SS50ZK1.

Offline Fredswat

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Re: RD200a & RD350
« Reply #61 on: February 28, 2019, 06:18:37 AM »
Thanks for the info.  Unfortunately those numbers are now no more,  lost to the blaster.  I was also a bit surprised how little trouble it was to separate the cases.  I think at some point in it's life it may have been apart before, looking at the heads of some of the crankcase bolts.

I used PJME a few years back on an Aprilia rs125 I did an engine rebuild on,  for the crank they seemed very professional and quite quick.  What didn't people on Facebook like about them ?

Chris   
« Last Edit: February 28, 2019, 07:44:58 AM by Fredswat »
74 RD200a
74 RD350A
77 RD400c
81 RD350LC
89 TDR 250
72 Kawasaki H1d
75 Kawasaki Z1b 
71 Suzuki T500R
76 Suzuki Gt750
89 Suzuki RGV250 Vj21
76 Honda cd175 
85 Honda c90
03 Aprilia RS125
48 Royal Enfield J2

Online stukey

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Re: RD200a & RD350
« Reply #62 on: February 28, 2019, 08:02:05 AM »
Probably the same (experts) who recommend the cheap pistons made of cheese :o :o
Rd 350 special can we get more than 70bnp?
Silver-dust 350b now with new owner
Barnfull of A/b stuff
and not forgetting the r6 streefighter
 R1Z 250

Offline rsvr1000

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Re: RD200a & RD350
« Reply #63 on: February 28, 2019, 09:02:03 AM »
Yes Fredswat. In Japan their year is -25. like 45 = 1970. Anyway am interested that you and rsvr1000 both recommending PJME. I liked the look of their site and mentioned it on Facebook Aircooled page and everyone told me to use Grampian Motors.

Also surprised the cases came apart so easily. I thought the tool was a must and something to push the crank out the LH case too. Or at least to draw it back in on re-assembly. I actually cracked my AS3 LH case trying to tap them apart, per the Haynes manual  :(



Everyone has their own opinions on where they have crank rebuilds or rebores done. PJME are local to me and I have been using PJME for over 15 years now and never had an issue they even resleeved the barrels on my RD400 7 years a go still going strong and sounds sweet . On every forum you will always have the expert who has an opinion  about everything but never see pics of thier own rebuilds  8) Grampian have also a good reputation so you have not done wrong it's just down to personnel preference .
« Last Edit: February 28, 2019, 09:14:20 AM by rsvr1000 »
GT250 X7,RD400, RD350 LC,CB50J, Multistrada 1200 S , Rd350 ypvs 31K, Suzuki TL1000r.

Offline Foy(notFox)

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Re: RD200a & RD350
« Reply #64 on: February 28, 2019, 09:06:31 AM »
haha stukey. funnily enough they didn't actually comment on PJME Fredswat but just said 'leave everything to Grampians'. I was saying 'was it best to send company different sizes of O/S pistons & rings and let them choose best ones for the bore needed'. Explained it was rare machine (CS3E) and was told again 'leave it to Grampians'.

I think the reason for this is that they do supply pistons. if you look at their site there are links to two piston manufacturers and they explain they are made in Taiwan and finished in another country (iirc) so that is perhaps why they were recommended but they can't supply pistons for every machine surely.

Also liked the fact that PJME site lists a price for re-sleeving. Could be an option for machines where O/S pistons/rings are scarce.   
« Last Edit: March 02, 2019, 01:03:36 AM by Foy(notFox) »
CS3B, AS3, RD125, RD250C, Honda SS50ZK1.

Offline Fredswat

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Re: RD200a & RD350
« Reply #65 on: March 01, 2019, 09:37:56 AM »
For those of you contemplating overhauling your Oil Pump,  I would say be very careful and be sure it needs new seals .  There are two tiny springs and pawls that hold the worm gear on .  Before I knew it I had lost the springs.  Luckily managed to find them 4 hours later in my ultrasonic cleaning tank.  Getting them back in and refitting the  gear took another hour and after a lot of head scratching and cursing.  Finally realised the best way was to Cellotape the pawls in against the spring pressure until I could slide the gear on.  Not going to do that again in a hurry If you can get away without taking the gear off the shaft then leave it alone.  on line video recommends dismantling the pump in a plastic bag.  Which is fine but no one suggests how to reassemble that really tricky bit
74 RD200a
74 RD350A
77 RD400c
81 RD350LC
89 TDR 250
72 Kawasaki H1d
75 Kawasaki Z1b 
71 Suzuki T500R
76 Suzuki Gt750
89 Suzuki RGV250 Vj21
76 Honda cd175 
85 Honda c90
03 Aprilia RS125
48 Royal Enfield J2

Offline Fredswat

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Re: RD200a & RD350
« Reply #66 on: March 01, 2019, 09:40:49 AM »
Barrels and Crank with PJM as of yesterday.  They don't do pistons for the RD200 so it looks like ebay here we go.  Waiting for PJM to get back to me with the measurements for the bores post rebore to see how much oversize they will have to be before I start bidding. 
74 RD200a
74 RD350A
77 RD400c
81 RD350LC
89 TDR 250
72 Kawasaki H1d
75 Kawasaki Z1b 
71 Suzuki T500R
76 Suzuki Gt750
89 Suzuki RGV250 Vj21
76 Honda cd175 
85 Honda c90
03 Aprilia RS125
48 Royal Enfield J2

Offline Foy(notFox)

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Re: RD200a & RD350
« Reply #67 on: March 02, 2019, 01:14:22 AM »
That was exactly my point on the Facebook post. No point sending a company pistons/rings that won't be big enough to cover the re-bore needed to make the barrels useable so I was thinking be armed with .25, .50 and .75 and send the lot then the company can return what they don't need. Problems with this approach are wasting money on unnecessary sets and a lot of stuff getting posted up and down the country plus months (or longer) waiting on the stuff popping up for sale.

Other option is what you've done, but then there's delay with your barrels sitting waiting on suitable pistons/rings.

It must be quite a common problem as I noticed PJMEs site saying something about a small charge if they need to go bigger to clear any damage. Something along those lines.

NB am sure Yambits do pistons for the RD200 up to +1.00 O/S and they aren't dear. Reason I remember this is that someone advised me to try them for RD125/AS3 oversizes and I noticed they didn't do as many for them as the RD200.

Also about the springs/plungers on the pump. I also lost one and eventually found a way to re-insert them without drama. Will need to check my thread as I can't remember now lol  :-\
« Last Edit: March 02, 2019, 10:09:56 PM by Foy(notFox) »
CS3B, AS3, RD125, RD250C, Honda SS50ZK1.

Offline Fredswat

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Re: RD200a & RD350
« Reply #68 on: March 02, 2019, 01:04:37 PM »
I would prefer to get genuine Yamaha pistons if I can.  I will check out your threads to see if I can find a simple way to replace the springs and pins in the oil pump Thanks
74 RD200a
74 RD350A
77 RD400c
81 RD350LC
89 TDR 250
72 Kawasaki H1d
75 Kawasaki Z1b 
71 Suzuki T500R
76 Suzuki Gt750
89 Suzuki RGV250 Vj21
76 Honda cd175 
85 Honda c90
03 Aprilia RS125
48 Royal Enfield J2

Offline Foy(notFox)

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Re: RD200a & RD350
« Reply #69 on: March 02, 2019, 10:33:33 PM »
I had a look at my own thread last night and am afraid the answer isn't there.

I think the answer is to push the pins in with an implement thin enough to slip the toothed gear down past the tool where it has the cut-outs. once the gear is back on you pull the tool away. would be easier with 2 people....

  • slide toothed-gear over two very thin screwdrivers
  • place springs and pins (relaxed) in pump part (don't know name) 
  • compress pins in with screwdrivers standing vertical
  • slide gear down screwdrivers (cutouts on gear aligned with pins)

or more simply two thin rods to squeeze pins in then assistant drops gear over the top of rods and works it down


if pins are compressed with tool smaller than cutouts on gear could gear be slip down over the tool?
« Last Edit: March 02, 2019, 10:52:15 PM by Foy(notFox) »
CS3B, AS3, RD125, RD250C, Honda SS50ZK1.

Offline Fredswat

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Re: RD200a & RD350
« Reply #70 on: March 03, 2019, 12:07:55 AM »
I think Cello-tape works.  Once I had the brain wave to use that it was relatively straight forward.  That method leaves your hands free to hold the shaft with one hand and slide the gear on with the other on your own without any additional help.  Just took me lots of fiddling and failed attempts before finally hitting on a method that would work.  The screwdrivers one needs a lot of dexterity and it's very easy to slip allowing the pawl and springs to ping off plus a willing and competent assistant is required. 
 
74 RD200a
74 RD350A
77 RD400c
81 RD350LC
89 TDR 250
72 Kawasaki H1d
75 Kawasaki Z1b 
71 Suzuki T500R
76 Suzuki Gt750
89 Suzuki RGV250 Vj21
76 Honda cd175 
85 Honda c90
03 Aprilia RS125
48 Royal Enfield J2

Offline Fredswat

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Re: RD200a & RD350
« Reply #71 on: March 09, 2019, 03:22:12 PM »
Little more progress today.  2nd oversize pistons arrived ready to send to PJ for rebore.  Painted and lacquered the RHS RD200 cases.  Managed to get a UK tail lamp bracket from Ebay (I will be selling a mint US spec bracket - Re chromed either with tail lamp or separate).  Blasted and painted the UK one. Also primed the RD200 cylinder heads ready for PJ1
74 RD200a
74 RD350A
77 RD400c
81 RD350LC
89 TDR 250
72 Kawasaki H1d
75 Kawasaki Z1b 
71 Suzuki T500R
76 Suzuki Gt750
89 Suzuki RGV250 Vj21
76 Honda cd175 
85 Honda c90
03 Aprilia RS125
48 Royal Enfield J2

Offline Foy(notFox)

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Re: RD200a & RD350
« Reply #72 on: March 12, 2019, 11:07:05 PM »
That was quick with the pistons! and good find with the rear bracket but it looks like someone has trimmed the edge off it. Possibly to make it fit a smaller number-plate.

Won't really be noticeable once it's on the bike tho  ;)
CS3B, AS3, RD125, RD250C, Honda SS50ZK1.

Offline Fredswat

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Re: RD200a & RD350
« Reply #73 on: March 13, 2019, 03:48:03 PM »
Yes they came within three days £60 for both pistons, rings, gudgeon pins and cir-clips.  They are SKE pistons but labelled with a Yamaha part number.  Apparently they are quite good  Japanese copies of the OEM ones from the eighties.  I know the number plate has been trimmed a bit but as you say it wont really show when a plate is on it.   
74 RD200a
74 RD350A
77 RD400c
81 RD350LC
89 TDR 250
72 Kawasaki H1d
75 Kawasaki Z1b 
71 Suzuki T500R
76 Suzuki Gt750
89 Suzuki RGV250 Vj21
76 Honda cd175 
85 Honda c90
03 Aprilia RS125
48 Royal Enfield J2

Offline Fredswat

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Re: RD200a & RD350
« Reply #74 on: March 21, 2019, 08:12:03 AM »
Got my Crank and Barrels back this week.  Speedy service from PJM :D Made a bit of progress with the outer cases by polishing off the paint on the raised bits.  I probably should have masked them,  but it didn't take too long.  Painted the cylinder heads and filed the fin edges for that crisp look.  I will be painting the barrels next and filing the fins same as heads.  I couldn't resist just putting the cases together with one of the out ones to get a feel for what the motor will look like when it's done .
74 RD200a
74 RD350A
77 RD400c
81 RD350LC
89 TDR 250
72 Kawasaki H1d
75 Kawasaki Z1b 
71 Suzuki T500R
76 Suzuki Gt750
89 Suzuki RGV250 Vj21
76 Honda cd175 
85 Honda c90
03 Aprilia RS125
48 Royal Enfield J2