Project Yamaha YZR500 part 2- Master Blaster!

Classic Motorcycle Mechanics|March 2020

Project Yamaha YZR500 part 2- Master Blaster!
With 160bhp going through it, the YZR clutch needs to be up to the job. Niall’s wasn’t! What else did he find lurking under the fairing?
NIALL MACKENZIE

The decision to give my YZR a full overhaul was mainly based on visual observations so it was no surprise that on closer inspection there was plenty more work to be done.

It started with brake fluid from the front master cylinder seeping down the righthand side of the nose cone melting the paint. Nothing can stop time taking its toll on seals, etc., so I knew there was probably much worse lurking beneath. If you follow my exploits in CMM you’ll know my go-to company for anything resto related these days is IDP Moto at Silverstone, so cue a consultation with boss man Daryll Young for expert advice.

With the bodywork removed we immediately saw some minor corrosion on the outer water pump casing and the cooling pipe that links the top two cylinders. My bike is an exotic animal, having lightweight magnesium crankcases and covers, but the downside is they’ll turn to dust if not looked after properly. This has always played on my mind and another important reason to bite the bullet and give this lovely bike a well deserved birthday. One end of the pipe was completely gone so we had a new insert expertly made up and then fitted and sealed with Araldite. There were also a few blowholes that we sealed from the inside.

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March 2020