I'm in the process of restoring this vintage bike. Thanks to all that helped identify it. In case you didn't read the thread I've decided to post a new thread detailing my efforts. here's pix of the bike after it was given to me.



As you can see it's ruff. The frame, handlebars, and shocks are very rusty. The few of the spokes on the rear rim have rusted thru. My original plans were to just to replace the spokes but I also found a crack in the rim so it's trash. The front rim appears to be newer and is pretty corroded but salvageable.
The handlebars were easy, I just replaced them with ones from a doner 86' Honda XR 80 I had from when I was a kid. Also changed over were the grips, levers, and motor shut off button. It took awhile to get all the cables switched over and adjusted but it was worth it. I also prefer them over the stock 175's because of my narrow shoulders.
Handlebar pix.

Since basically everything metal that could rust did stripping was not an option. I went over everything with a 3M rust wheel mounted on a drill followed by a 60 grit flap wheel and then a 120 flap wheel. Hard to reach areas were either hand sanded or hit with a Nyalox wheel. Also the forks and triple clamp were done.
Kickstand pix
Before

After

Shock pix
Before

After

Forks pix
Before

After

Now heres where I got a break and a good one. I drained the oil and It was clear! The piston and cylinder look real good. The piston shows an overbore of .25 was done. Compression checks out @ 150psi!
The tank looks good overall. There is some rust pitting and a small dent on the right side. The gas was left in it for 20 some odd years and was jelly. The petcot was turned off but frozen in that position. I cleaned the tank with mineral spirits and soaked the petcot in the same stuff and it's free now. I popped the dent out of the tank with good results.
Tank pix
Dent
http://i31.photobuck..._b/DSCF2544.jpg
http://i31.photobuck..._b/DSCF2545.jpg
Now it's gone
http://i31.photobuck..._b/DSCF2559.jpg
http://i31.photobuck..._b/DSCF2560.jpg
That's about it for now. I've only had it for 3 weeks. I'm still waiting on parts to get here like the missing exhaust, stator, stator cover, and oil injector cover. Questions comments and opinions are welcome...PB

I am amazed that you were able to clean up parts that much. :thumbsup:

What did you use to get the dents out of the tank?
I have a couple of dented tanks. Light rust inside of one.

Also, I need to buff some aluminum and remove light rust on some steel parts.

I am amazed myself :) I used a product from Simoniz? that I picked up from Autozone for $20. 3 trys and it all popped.
I soaked the entire bike in spray oil overnight tohelp loosen it all up just wash it off before sanding. The 3M rust cutting wheel does wonders. I picked mine up from True Value but I'm sure it's available other places. After that your left with some bad marks so some final sanding will have to be done.
Not sure what the rims are made of but I used coarse steel wool followed by a finer grade and then hand sanding with 400 grit. That took the rims from this:

To this:

Looks like a lot of work went into this little puppy. It turned out fine. I'll know where to come to for advice when I start on another one of my treasures. You always hope to fine a primo vintage bike in a barn or somewhere but this is what I ususally end up with. I can't complain it keeps me occupied for a year or so anyway. I've found I don't get banged up racing them as bad, by just restoring them and selling or trading the off.

Thanks. It coming along nicely. I enjoy the challenge of making something from nothing. I also plan on riding this thing and getting it all scratched up and muddy again :)...PB

Nice job, keep up the great work. I love a vintage restore!!!!!!!!!!! I love them old Yamahas!!

Just playing the waiting game at this point. I ordered Rust Bullet black satin paint for the frame. I consider it insurance against current and future rust since there is some pitting that I wasn't willing to sand out maybe weakening the frame in the process.
I did find a flexible plastic paint that matches the vintage Yamaha yellow pretty good. I used it to paint over my old red front number plate from a 86' XR 80. I didn't sand it so it wouldn't look too new and clash. I did prep it by wiping it down with mineral spirits to degrease/dewax it followed by washing it with dish washing soap.
Here's a pic of the plastic I painted. I'm not painting the tank or fender, they are only there for color comparison. I also picked up correct side covers last night for $10 on Ebay. I will be painting them.

Pic of the paint I used in case someone is interested.

Color code.

Try this with regular paint! Excellent product.

http://www.afegraphics.com/mcbikes.htm They may have those XL600 decals you needed..

For your Yamaha, should you decide to paint it - you can get the decals at:

I was able to get the first coat of the Rust bullet on today. Tomorrow I'll do the second coat then the black satin. I also finished sanding the other half of the front rim so all that's left on it is a little polishing. There is still a bit of pitting but it should shine up real nice.
Frame pic:

Note- Rust bullet is grey. This is not the color it's gong to be!...PB

JPinLA said:

Thanks for the link but I don't see my bike on that site?

Alright the Rust bullet is dry. I've decided to go ahead and strip the bike down to the frame so I can final sand all the details and spray in all those tight places.

I noticed a crack in the frame while I was sanding. Out came the torch. Not the prettiest weld ever but I wanted to make sure it was filled.

I ground it down with the ol' Dremel follow by a 60 grit flap wheel and then a 120 grit flap wheel. I wont tell if you don't :)

Here it is hanging in the garage, wiped down with mineral spirits followed by a water wipe and ready to prime.

I used Rustoleum 'rusty metal' primer.

DONE!

Now yer talking!!!!

You can get your decals here:

http://stores.ebay.c...hicReproduction

:)

Real nice. I had a 73 mx250 with a weiseco piston. Great bike!

gialinn said:

Thanks man!
Not much to update. I did finally get the springs to shine.

Today I sanded and painted the rest of the shock. I'll post a finished pic tomorrow when it's dry...PB

Shocks are done!
Definitely need a before and after on this one. I know I could have gone on Ebay and probably picked up a set cheap but whats the fun in that?
Before:

After:

I painted the shocks with a gloss enamel. Not much left really. The old carb has some of it's black paint on it from long ago. I think I'll have to do something with that. I like the look of the natural metal on carbs. As usual I'm waiting on parts namely a 175 bottom end. The case on the original is chunked where the shift lever bolts up. I can also use the magneto and all the covers missing on the original...PB

Went ahead and did some work on my good cylinder and head.



Also cleaned up the CDI and coil. Not much work on them but worth a shot...PB

lookin GOOD! One of these days, if i ever find the right color of paint for the engine cases, i'll have my '74 XL 350 back together. I figure i've got about 15 hrs into polishing the cylinder and head alone... ahhhhh, the things we waste our time on!! (that was a happy sigh).

I'm thinking of sanding my cases and painting them satin black like the frame. I'll probably keep the cylinder and head natural. I wouldn't mind sealing it if I could find something suitable.
Don't get me started on polishing:) I have a 3/4 buffer with too many hours on it from shining up everything in the engine bay of my Mustang. Nice to see a fellow polisher on here....PB

the only thing i really polished was the valve adjuster covers and the points cover, everything else was degreased, taped off, and bead blasted, untaped, de-beaded, new seals, re-assembled, and wire wheeled. Takes a while to do the valves right.