From the beginning it looked like it was once underwater.

Nice one Geoff. I hope mine eventually turns out to be as clean as that on the inside, gives me hope.

Good luck with the rest ofthe strip.

Will you just be going with the Haynes book or do you know of a better one for these? I don't think there is a clymer for these is there????

jwdg298 wrote:
Will you just be going with the Haynes book or do you know of a better one for these? I don't think there is a clymer for these is there????

Been checking today Gerry, no clymer manual so will have to be the Haynes book of lies......

There's a factory workshop manual here

http://www.repairmanualclub.com/motoman ... C&limit=90

You have to join but it's free, not sure on the legality.

I think the needle jets wear quite quickly on these carbs, same ones used on TDM850s & ducati 900ss, which also start to run rich quickly.

Rick

I have a Pdf version of the Yam Manual as well as parts book and Owners hand book if you are interested. You could send me a PM and I can send it to you some how.

I tried the link to the manuals and kept getting an error message, but after a google search and I found this site.

http://www.carlsalter.com/motorcycle-manuals.asp

I have just downloaded the pdf service manual for the super ten, took about 10 mins and it looks pretty good with lots of comprehensive detail (425 page Yamaha book?)

I am just downloading the other zip file one but I think it may be the Haynes one, willl let you know.

thanks Gerry...

She is coming along nicely Geoff One thing you might want to have a peek at is the clutch housing. You will have to remove the springs and all the clutch plates. once they are off, have a look at the tubes that the spring bolts screw into. if there is too much wear the springs tend to stick and the clutch slips. I have had a look at mine and there is some wear but i think a bit of gentle filing will sort it out



You are very lucky not to have to strip the motor I am replacing my gearbox bearings and it is a fekin pain in the crotch so far. I have this very disturbing grinding noise when the bike is in gear. It doesnt seem to matter what gear its in either. Its more pronounced when the motor is under a bit of load. So yet another expense to the project. I just hope my wife doesnt see my visa statement at the end of the month. It might cause the first ever bike rebuild divorce this forum has seen

One strange thing, the lower left head/barrel stud is covered in emulsified oil, no evidence of why...
both head & base gaskets are good, no leaks anywhere..... maybe its condensation..... Dave, what do you think?

Emulsified oil is a sure sign of coolant leaking into oil system. The engine has to be running to cause the emulsion. Just mixing oil and water won't do it.
The exception is ATF, it contains artificial emulsifiers and forms mayonnaise on contact with water.
I would say the head gasket was leaking near that stud.

I was loving this very brave re-build....