South African rebuild of a XTZ 750

[CharlieGreger]

The engine is in at last I am busy with the electrical rats nest at the moment, and i am hoping to have it done by the end of the week. But judging the time i actually get to spend in the garage these days i might still be at it in three weeks from now

I had thought to spray the whole thing silver or black,but in the end decided to go with the silver and black idea.





after having filed the fins back to metal.



I was wondering how to paint the 'YAMAHA' on the clutch cover silver, but its embossed into the plate and for love nor money couldn't get it to look decent. So i binned the idea and just painted it black. Still, i quite like the look of it as it is. I am just praying that once the bike is running again the paint doesn't come off cause i don't fancy pulling the thing apart again just to spray the motor.

I had some trouble getting the engine back in on my own. I had to use a small trolley jack and a heap of luck hoping the bike wouldnt fall over as the motor was going in. How i ended up doing it was, I bolted the two pieces of the frame loosely to the motor, then placed the whole lot onto a block of wood on the jack. Then manouvered the lot into place and jacked it up into place. quickly slotted in the swing arm bolt and two at the front and bob was my uncle! I dont recommend this to anyone, but at the time i had to do it on my own with not much in the way of help from the tools i have. If you have a extra pair of hands, be that your mates or your wifes, it will make life a lot easier and less stressful. I think it was sheer luck that the motor didnt fall off the jack and break something expensive. So not the brightest idea i have ever had

Anyway, the motor survived re-installation and here she is









And even had time to start adding some of the decals that Gustafsson sent from far far away

I am going to replace the screen at a later date, so in the mean time i have sprayed it white and added some art to it. looks way better than the manky original.





.......hmmmm...... now where the hell are my other photos??? forfucksakesman!!!

[Mezo]

Absolutely bloody fantastic.

At last someone has done a Chesterfield & it looks brilliant, how i did my YAMAHA on that plate was to wait till the paint dried & carefully sanded it back with some wet & dry, i cocked it up several times i must admit & had to re do the thing all over. And as for the engine instal i read a tip where you lay the frame & motor on its side on a bit of carpet & slide her in that way, that`s how i did it on my 3AJ that`s how i got the engines out on the 34L`s, much easier if your working alone.

Nice one, well please for you.

Mezo.

[Danjet600]

mate thats come up nice, that painted screen looks gooood

[xtjoe]

Neat Charlie man,well done

[55W1985]

Charlie you has sparked into me the idea of owing a ST now!!!!!!
FANTASTIC results!I love the black painted engine......
Now for the letters in silver......let them cut in stainless sheet or aluminum.They do that kind of work with water.Then insert them in the recessed part.
Keep the pics comming!

[vander]

Your biki is looking aboslutely phantastic!


I want one like this in my living room:



I might steal your color scheme for my engine, which I am starting to take apart right now.

[CharlieGreger]

Thank you.... Thank you!!! I will take more photos when the weather improves!!

I tell you, actually finishing this project is somewhat bitter sweet in that I am VERY happy to have my bike on the road again and to be back in the saddle after a six month break from any form of riding, yet i find myself feeling somewhat bleak in that i now don't have another bike project!! But fear not. I have seen a XT 550 up for grabs for a fair price, although it has been used as an off road bike for some time now.... But i am sure it can be resurrected.

as for my engines colour scheme. credit for that idea has to go to Mezo and Geoff. After much faffing and cursing i eventually settled on what artwork to stick on and what to leave off and set about spraying my clear coat. How i have done all my spraying so far is to spray a light coat first , then once it becomes tacky after 5 minutes or so, spray the first actual coat of paint. The initial coat is more of a "bonding coat" and helps to reduce any paint from running. Then the other two coats get added at intervals, each coat applied having more paint than the previous. So in total, she has had a coat of primer, two coats of pearl, a single coat of white over everything, then taped off the red sections which received two coats of red ( the front of the tank where the seat rubs against ended up with a heavy third coat ), the yellow stripes had two as well, and the rest of the white another heavy coat of white...... and then two clear coats

fuck it.... no wonder she feels heavy.

Question here for the spray paint buffs, While i was spraying my clear coat, i noticed that a white powder like residue was left behind after i had finished spraying a coat. at first i had a panic and much swearing ensued thinking i had made a royal fuck up... my spray gun was dirty.... or my paint was defective. So i waited for an hour or two for it to dry and was thinking i would have to sand it off again, but when i touched it to see if it was still tacky or had dried, this powdery residue just wiped off leaving a fantastic coat behind?????? I would be inclined to think i am doing something wrong when spraying, perhaps the gun is set too fine or my spraying pressure is incorrect??? any ideas?

[Mezo]

Whats the temp Charlie? are you sure that`s not "bloom" i fucked up a few jobs by spraying early in the morning when it was to cold & i got this milky finish to my job.

Edit: That can be fixed Charlie, let it dry & then wet & dry with 1200, then apply your clear coat once more (mezo is no paint expert & readers should always consult a professional)

Edit Edit: Charlie send Just Dan a PM as he is shit hot with paint (ex painter) it may be crap in your gun & i think its best to ask a man that knows.

Hey this bike building gets addictive eh.

Look at Geoff, he sure has Tenreitis & apparently is being treated for his condition (wife & rolling pin)

Mezo.

[ActionManMelb]

Conversely, if you spray on a hot,low humidity weather day,
the paint can dry before it hits the surface and just land as a dry tacky powder.


Experiment with different days and techniques, if you still have problems talk to the paint supplier
or take a visit to your local auto smash repairer and talk to the guy who wields the paint gun.

[CharlieGreger]

Come to think of it i did my clear coat spraying on a hot day. so perhaps it was the paint drying before it landed?? I still have to spray my two side cover with clear coat after i have the new decals on. the ones from Gustafsson were a tad big and I couldn't get them to sit without wrinkling up and bubbling. I tried the soapy water trick and the low heat idea to no avail. So i have had smaller versions of the ones he sent made up and will stick them on when i get a gap.

I will have a look when spraying the side panels and see if it happens again. At least i didn't have to respray my clear coat in the end which is always a plus!!