Author Topic: RD200a & RD350  (Read 22220 times)

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Offline Fredswat

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Re: RD200a & RD350
« Reply #240 on: April 11, 2020, 03:12:17 PM »
Well done matey!

Have you tried a) the adjustment screw on the horn or b) taking it apart? Sorry if I've asked that already!
Hi yes tried both disassembly and adjustment . Cleaned internal contacts still no go .
The horn comprises mainly a set of contact breaker points and an electro magnet - clean the points up and you might be good to go.

Regards.

Alan
74 RD200a
74 RD350A
77 RD400c
81 RD350LC
89 TDR 250
72 Kawasaki H1d
75 Kawasaki Z1b 
06 Kawasaki Z1000
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 #241 on: April 11, 2020, 03:16:43 PM »
Hi Chris
People knock Yambits a lot, however they do have an excellent Returns policy. You may return unopened, non special order parts within 7 days of receipt.
https://yambits.co.uk/shipping.php?

osCsid=h8622vtn82ophpvj7vcb8sbhv4

Hi Mike thanks. I didn't know that. I could save myself £20 of unnecessary spend. I always seem to get to a point where it's easy to pour in extra money in a rush to get things finished.
Have a read.
-Mike
74 RD200a
74 RD350A
77 RD400c
81 RD350LC
89 TDR 250
72 Kawasaki H1d
75 Kawasaki Z1b 
06 Kawasaki Z1000
71 Suzuki T500R
76 Suzuki Gt750
89 Suzuki RGV250 Vj21
76 Honda cd175 
85 Honda c90
03 Aprilia RS125
48 Royal Enfield J2

Online Motty

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Re: RD200a & RD350
« Reply #242 on: April 11, 2020, 06:32:35 PM »
Did you replace the entire master cylinder assembly or use a rebuild kit?

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Terry Pratchett

Offline Fredswat

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Re: RD200a & RD350
« Reply #243 on: April 11, 2020, 06:40:34 PM »
Hi Motty
I initially blasted and rubbed down the interior of the original Master cylinder and fitted an overhaul kit.  That was what I was trying to bleed for about 2 hours with little success and a lot of wasted brake fluid.  What I have now done is buy a complete new pattern Master cylinder including brake lever from Yambits.  It took no time to successfully bleed that one. 
74 RD200a
74 RD350A
77 RD400c
81 RD350LC
89 TDR 250
72 Kawasaki H1d
75 Kawasaki Z1b 
06 Kawasaki Z1000
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 #244 on: June 09, 2020, 04:03:53 PM »
No updates for a while.  I have been trying to get the Rd350 finished and started.  I got the point where everything was ready to go ie. Carbs adjusted, timing set, temporary fuel tank hooked up, electrics fully functioning.  Turned on the ignition and started to try to kick it over.  I also sprayed easy start into the plug holes to give it a bit of a help.  No joy :-\. I know the timing is spot on and the carbs have been off twice to make sure everything is ok with float heights and needle settings.  When I first put the crank in I thought it was a bit tight in places as you turned it over.  I called at that time and the man at PJE said it would probably get easier when the generator and other bits were fitted.  It's actually become harder.  It is quite difficult to kick over.  All my other strokers you can kick over with your hand without the plugs in but this one is definitely too tight for that.  I decided to strip it down and investigate.  So I am now at the stage where I have taken the engine back out of the bike and removed the clutch and generator.  I called PJE and have taken it to Paul the man there.  When he looked at it and tried to turn it over by hand he agrees it is a bit tighter than it should be.  He is going to split the cases and report back on what he finds.  I will be so experienced in taking Yamaha twin engines out and putting them back in by the time this is finished.  I have seen that others on the forum have had experiences with tight crankshafts in the past   
74 RD200a
74 RD350A
77 RD400c
81 RD350LC
89 TDR 250
72 Kawasaki H1d
75 Kawasaki Z1b 
06 Kawasaki Z1000
71 Suzuki T500R
76 Suzuki Gt750
89 Suzuki RGV250 Vj21
76 Honda cd175 
85 Honda c90
03 Aprilia RS125
48 Royal Enfield J2

Online Motty

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Re: RD200a & RD350
« Reply #245 on: June 09, 2020, 05:28:36 PM »
I think there was a recent topic where a tight crankshaft was discussed?

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“...inside every old person is a young person wondering what the f*@k happened.”
Terry Pratchett

Online 5port

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Re: RD200a & RD350
« Reply #246 on: June 09, 2020, 05:39:24 PM »
Hi Fredswat, Sorry to hear your woes!   ???
Obviously the crank normally spins quite easy.  The main drag is going to be the pistons/rings in the bores and of course the compression.  With the plugs out, even a brand new engine should spin over by a finger on the kicker.  I guess the bearing pips and the C ring have been discussed?  Thanks for the update!  Cheers

5port 
5port

Offline Fredswat

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Re: RD200a & RD350
« Reply #247 on: June 11, 2020, 03:29:37 PM »
Found out how stupid I am today. I went to PJ to get my cases back so that I can clean them up ready for crank refit.  Paul pointed out that I had tried to align the pips on the bearings with the oil well holes in the cases not the slots . No wonder I couldn't get it to line up what a numpty.  I have managed to wreck the two new inner bearings which  mean PJ are splitting the crank and replacing those.  Spent this afternoon stripping down the cases and blasting them again to remove the  "excessive" amount of sealant I had used (according to Paul).  You can see where the pips have been pressed into the upper case  as I tightened it up.  Oh well you live and learn
74 RD200a
74 RD350A
77 RD400c
81 RD350LC
89 TDR 250
72 Kawasaki H1d
75 Kawasaki Z1b 
06 Kawasaki Z1000
71 Suzuki T500R
76 Suzuki Gt750
89 Suzuki RGV250 Vj21
76 Honda cd175 
85 Honda c90
03 Aprilia RS125
48 Royal Enfield J2

Online 5port

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Re: RD200a & RD350
« Reply #248 on: June 11, 2020, 06:18:27 PM »
Very honest write-up Fredswat!  :) :) :)
Lots of these engines have had that mistake.  Just a shame that it has cost you.  However, no-one that has rebuilt an engine has not made mistakes!  :D
BTW, you do need enough sealant to do the job.  I notice how the OE stuff has runs!.  Cheers!

5port
5port

Offline Fredswat

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Re: RD200a & RD350
« Reply #249 on: June 27, 2020, 11:08:35 AM »
Crank going in for the third time .  After the shenanigans of the crank bearing pips,  I have the crank back and decided to fit it today and close up the cases. I was super careful this time to line up the pips with the slots in the lower case.  I re-tapped the M6 threaded holes in the lower case and  put a die down the bolts to remove residual sealer (Yamibond).  I dry fitted the cases together first to make sure it all went together and the crank rotated freely before final assembly.  I squeezed the sealer into an old tobacco tin and applied it super carefully with a small flat bladed screwdriver a bit like using a pallet knife .  Put the cases together again super carefully and nipped up the top case bolts. Flipped it over and fitted the nuts and washers.  After torqueing the lower nuts, torqued the top ones.  Guess what it rotates beautifully  :D.  Cleaned any excess sealer off the crank journals.  Had a celebratory cup of coffee. In now turns over with finger pressure    
74 RD200a
74 RD350A
77 RD400c
81 RD350LC
89 TDR 250
72 Kawasaki H1d
75 Kawasaki Z1b 
06 Kawasaki Z1000
71 Suzuki T500R
76 Suzuki Gt750
89 Suzuki RGV250 Vj21
76 Honda cd175 
85 Honda c90
03 Aprilia RS125
48 Royal Enfield J2

Offline Gr8uncleal

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Re: RD200a & RD350
« Reply #250 on: June 27, 2020, 11:30:01 AM »
A Titleist golf ball user I see (PROV1 or PROV1X by any chance?)! Clearly a man with good taste and deep pockets!  :D :D :D

My local course has eight lakes and, when I used to play, I would never use a new Titleist on any of the water holes - £3 competition entry fee, but lose £10 worth of balls, no thanks! :o :o :o :o :o

Gr8auntiepat is off to play in an hour or so's time.

Oh, well done on the engine by the way! ;) :D
Yam RD200DX (Gr8auntiepat's)
Yam FZX700 Fazer
Yam RD400 bitsa
Yam RD350B rough
Yam RT2 almost finished
Yam DT360A almost finished
Suzi GT550J just started
Suzi 1250 Bandit regular rider
Yam RD125B (probably!) now being reassembled
Yam AS3 in boxes

Offline Fredswat

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Re: RD200a & RD350
« Reply #251 on: June 27, 2020, 12:00:11 PM »
I only buy Lake balls.  I try to use Pro V1's if I can. Supposed to be playing today although weather is not looking good, it's hammering down here.  I might go back up the shed and do a bit more engine reassembly instead 
74 RD200a
74 RD350A
77 RD400c
81 RD350LC
89 TDR 250
72 Kawasaki H1d
75 Kawasaki Z1b 
06 Kawasaki Z1000
71 Suzuki T500R
76 Suzuki Gt750
89 Suzuki RGV250 Vj21
76 Honda cd175 
85 Honda c90
03 Aprilia RS125
48 Royal Enfield J2

Online Motty

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Re: RD200a & RD350
« Reply #252 on: June 27, 2020, 01:40:44 PM »
Well done, a positive update

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“...inside every old person is a young person wondering what the f*@k happened.”
Terry Pratchett

Offline Fredswat

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Re: RD200a & RD350
« Reply #253 on: June 29, 2020, 02:31:12 PM »
Getting back towards where I was a few weeks back. Engine rebuilt, ignition timing set. It's ready to go back in again.  I will be doing that tomorrow.  I think I will take the heads back off just to give myself some clearance.  Anyone got any thoughts on when to fit the Y shaped aircleaner duct onto the air box? It's a complete bast&*^d with the cabs fitted.
 
74 RD200a
74 RD350A
77 RD400c
81 RD350LC
89 TDR 250
72 Kawasaki H1d
75 Kawasaki Z1b 
06 Kawasaki Z1000
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 #254 on: June 30, 2020, 01:19:22 PM »
Progress today. I'm getting quicker at this 2 hours to get the engine back in, fit carbs, exhaust headers, Oil pump side, connect all the pipes, tacho cable, clutch cable, throttle cables, drive chain etc.  I guess it comes from doing it about four times recently for various reasons.  Anyway nearly back the point of trying start it again. Just going to leave it overnight with some tissue underneath to make sure I don't have any slow oil leaks now that I have filled the gearbox again. I found it much easier to fit the Air cleaner duct to the airbox without the engine in.  Once the big band clamp is tightened it stays in place when you are jiggling the carbs about to get them to fit between the inlet rubbers and the air cleaner ducts.  If the carbs are fitted to the inlet rubber first I have found it much more difficult to get the duct in and connected to the bottom of the airbox
  
74 RD200a
74 RD350A
77 RD400c
81 RD350LC
89 TDR 250
72 Kawasaki H1d
75 Kawasaki Z1b 
06 Kawasaki Z1000
71 Suzuki T500R
76 Suzuki Gt750
89 Suzuki RGV250 Vj21
76 Honda cd175 
85 Honda c90
03 Aprilia RS125
48 Royal Enfield J2