Wednesday, July 15, 2015

Rebuilding Yamaha Chassis

After reassembling the front fork I put all the wiring back in place. If you leave this till later is gonna be very fiddly. Before I took the wiring out I made lots of pics but even with those pics it was a bit of a puzzle to connect everything the right way. Actually I still don't know if it's all good; most of it can only be tested with the engine running.

Wiring diagram Yamaha 100 LS3 1972
Wiring diagram Yamaha 100 LS3 1972

Part number tag still on the original wiring harness Yamaha LS3
Part number tag still on the original wiring harness 

Original Wiring in head light Yamaha LS3
Original Wiring head light Yamaha LS3

Next things were the handle bar, rear fender, tail light, indicators, rear wheel and freshly sprayed sprocket. The switch handle also needed some TLC and soldering. The original handle bar was stripped down, sanded and nickel plated and the aftermarket throttle handle was replaced with a NOS one including a new throttle cable and oil pump cable.

Taking the switch handle apart - Yamaha LS3 1972
Taking the switch handle apart 

Rusty indicator switch Yamaha LS3
Rusty indicator switch

Indicator switch mechanism Yamaha LS3 100cc
Indicator switch mechanism and horn button

Indicator switch mechanism
Cleaning indicator switch mechanism

Rebuilding Yamaha LS3 handle bar
Rebuilding Yamaha LS3 handle bar

Tail light and rear fender Yamaha LS3
Tail light and rear fender Yamaha LS3

Painted original 36 rear sprocket Yamaha LS3 1972
Painted original 36 rear sprocket Yamaha LS3 1972

Rear wheel Yamaha LS3
Rear wheel Yamaha LS3

Rear mud guard Yamaha LS3 - Close up
Rear mud guard Yamaha LS3 - Close up

Followed by rear shockers, front fender, front wheel and most cables. 

Nightshift: mounting front mud guard Yamaha LS3
Night shift: mounting front fender

Left side front wheel Yamaha LS3
Left side front wheel Yamaha LS3

Right side front wheel Yamaha LS2 1972
Right side front wheel Yamaha LS3

Rear wheel with brake rod and tension bar
Rear wheel with brake rod and tension bar

Break switch rear
Break switch rear

As with most older bikes not all parts are available anymore, so sometimes you have to be creative and make your own stuff. The old dampers for the right side cover mountings were almost perished and I couldn't find them so I made them from an old inner tube. In the middle of the tube is a weld which looks almost the same as the original part but above all it's functional.

Making cover dampers from an old inner tube - Yamaha LS3
Making cover dampers from an old inner tube 

Time to bring back the seventies! Mounting the side covers and a loose fit of the fuel tank, at this moment I'm starting to see why I'm putting all those hours in this once basket case, enough time has passed for the LS3 to be cool again :).

Oil tank with new oil level gauge
Oil tank with new oil level gauge

Fitting fuel tank Yamaha 100cc 1972
Fitting fuel tank

Right side fuel tank, cover and rear shocker
Right side fuel tank, cover and rear shocker

Right side fuel tank, cover and rear shocker Yamaha LS3
Right side fuel tank, cover and rear shocker

Luckily I took of the original sticker of the oil tank with a razor blade and kept it in a safe spot. Before putting on the clear coat I put it back on the oil tank with some transfer tape. In this pic you can also see the metallic silver shining trough the red dye/clear coats; That's what they call "candy".

Two stroke only !!
Two stroke only !!

Chrome chain guard - Yamaha LS3
Chrome chain guard - Yamaha LS3

Exhaust
Exhaust

The buddy seat was almost ready. I only had to put on the original strap with the chrome button bolts. But because the new buddy seat had the bolts welded on I first had to carefully drill 'm out. The original bolts and chrome "buttons" were stripped of their old chrome, cleaned, sanded and nickel plated.

Welded bolts new buddy seat Yamaha LS3
Welded bolts new buddy seat

Original bolt with pin in place


Yes, it's not in the middle, but that's how it should be


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