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Spam16v

05 WR revival build.

31 posts in this topic

Well, it's 10 years old, blown up but it's mine. Didn't really notice any significant builds in the top few pages so I'll clutter this forum with my non fuel injected, controlled fuel leak having, steel framed pile of crap!

In case you didn't notice my previous two NOOB posts I bought an 05 that had a botched clutch install. Bolt backed out and dumped aluminum into the transmission and blew the teeth off 3rd, 4th & 5th as well as locked up all the trans bearings. Came with 17/19 wheelset and 18/21 dirt wheels which was cool.

It was ugly... Plastics -trashed, and overall a bit of patina. @still2smokin sold me a bottom end because he's awesome and held it until I made sure I made the purchase, double awesome. Then came the online spending and tear down. Got a dry erase marker lit off and started forming a list to suck my wallet dry.

Acerbis plastic set, plain Jane decal set from eBay, lever set, grips, gasket kit, ring set, countershaft sprocket & seal kit, used Yzf450 Ti slip on (have FMF head pipe), polisport led tail light for the MX rear fender, new ECU rubber holder thing, OEM WR450F rear fender decals, throttle tube, vent lines, shifter, bolt kit, silicone radiator hose set, chain slider, steering bearings, TT headlight switch, and a few other things.

Frame is at media blaster right now and I'll powdercoat it myself (6'x5'x4' oven on tap). Rest I'll prep and clean myself... Screw stripping a MC frame. I looped a hose in the tank nipples with worm clamps. Silicone capped the top vent and put a bolt with a crush washer in the dip stick hole. No sand can get in as long I'm on the watch. Going to do the bars, trees, pegs, frame, kick stand, swing arm, subframe and a bunch of brackets semi-gloss black. It's always loaded and I'm not changing the gun out... Any color as long as it's black!

Here's some pictures of the disaster area that is my 2 car attached garage. Harbor Freight lift table, and a Forward 2 post above ground automotive lift make it pretty handy. The boxes are on the way with all the goods, so waiting on media and a dozen boxes of stuff to come.

Bring on the advice or comments. Thanks everyone. -Zac

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I love builds! Will be following this one closely. My first request is a pic of your tail light. I just replaced my rear fender today with an mx style.

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Here's the one someone put in a DRZ I bought & then sold. Super small, super light. DRZ had a subframe, but without one I knew lighter was better for the WR. eBay $30 shipped... It's getting head and tail lights, no turns... Riding dirty I suppose. Won't see a lot of street action anyway. ImageUploadedByThumper Talk1446339065.417250.jpg

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Well, I said screw the stock skid mounts after the frame came back from media, they suck. Welded in some cold rolled quick. UMHW material gets cut up after powder coat to make a neat and tidy glide plate that will drain.

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THumpertalk lost the post wher i detailed the refresh of my old wr450.       I still very much regret selling that bike for that piece of shit KTM450 that I had at the time.  (not all KTM's are bad, just the one I had)

 

I still have a spot saved in my garage for my next WR450  (probably January) 

 

Here are the pics from my build a couple of years ago.   Its a lot of them, step by step, from beginning to end. 

 

enjoy

 

http://www.pdis.com/stuff/WR450/

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THumpertalk lost the post wher i detailed the refresh of my old wr450. I still very much regret selling that bike for that piece of shit KTM450 that I had at the time. (not all KTM's are bad, just the one I had)

I still have a spot saved in my garage for my next WR450 (probably January)

Here are the pics from my build a couple of years ago. Its a lot of them, step by step, from beginning to end.

enjoy

http://www.pdis.com/stuff/WR450/

I'm doing a lot of similar things. I did a lot of eBay, RMATV and Amazon for everything I put in my first or second post. Waiting for a Ron Ayers package to put my engine together. Rings, cam chain and some other oem crap.

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I'm doing a lot of similar things. I did a lot of eBay, RMATV and Amazon for everything I put in my first or second post. Waiting for a Ron Ayers package to put my engine together. Rings, cam chain and some other oem crap.

Ebay is your friend.    Its mine too.    

 

One of the images in my folder is the actual budget of what I spent for everything.    I hope it gives you a good reference.

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Ebay is your friend. Its mine too.

One of the images in my folder is the actual budget of what I spent for everything. I hope it gives you a good reference.

I saw that file and I'm going a little more above and beyond your list since mine started as a basket case needing more noteworthy repair to get up to par along with treating myself a little, but mostly the same stuff.

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I got lucky in the sense that mine did not need any bottom end work.  I was amazed that the crank and rod was in great shape.  At the time of the tear down, it had been about 7 years and at least 2000 hours...   at least...     I was putting in the second piston.   WR's are as reliable as an anvil.   Heavy as an avil too...   

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Still lighter than my old DRZ's... And more powerful too. All my parts are in hand for the engine. Going to attempt to begin cleaning and prepping for assembly tomorrow when I get out of work at 6am. I need to inspect the chain guides I have in a bag that I didn't put a watchful eye on yet, and make sure I don't need any more parts besides the cam chain tensioner. One more Ron Ayers order and powdercoating the frame and sub assemblies next Wednesday. Cleaned my work area so I'll post some stupid work bench pics...

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ImageUploadedByThumper Talk1448318638.715616.jpgImageUploadedByThumper Talk1448318648.967704.jpgImageUploadedByThumper Talk1448318682.715005.jpg

Well it's a roller. Couple three hours progress invested so far. Want to get the engine built tomorrow.

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And now I need an exhaust lifter bucket. Cam is flawless, mics out perfect without any evidence of wear. End gaps checked out ok, cylinder lightly honed. Need a stator puller to change the cam chain and begin assembling the lump.

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Some advice on the engine rebuild - upgrade the shift detent to 06 parts.

Which particular detent items? Have to order some other stuff from Yamaha anyway.

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Sorry, I've tossed-out the paperwork I had on it, but they can be identified by comparing parts lists for the shift detent mechanism for the 05 and 06 models.  From memory there are 4 parts involved - they have different part numbers.  The total cost of these is of the order of $70.  I replaced them in conjunction with replacing a number of transmission parts in my 05 after I had a 5th gear selection failure.  On inspecting the failure it seemed to me it could have been caused by the shift drum not rotating enough to fully engage the gears.  The fact that Yamaha made changes to the shift detent mechanism between 05 and 06 led me suspect it might have something to do with it. 

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Well, gonna get it together and see if it runs. I can always lay it over and do work on the shift mechanism side. I guess the decomp wear on the lifter is normal. So it's going back together. Bolt the cams in, check the valves and dump the lump in is the morning's plan before the family rat race. I already smoked two turkeys and baked pies... Time to show up and watch people get fatter tomorrow.

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ImageUploadedByThumper Talk1448678578.251760.jpg

Got the lump mounted in the frame and the lines on. Have to pull the subframe back off and put the battery box in the top of the air box since I forgot it. Hope to get most of the cables hooked up, controls sorted, exhaust on, side panels mounted and such tomorrow. Quick and basic carb clean with fresh vent lines, I HATE yellowed stiff carb vent lines...

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Well ?   How is it going ?

 

I hope you didn't let Christmas get in the way of your rebuild progress .

Edited by still2smokin

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