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Thread: Restoring Yamaha 100cc (YB100, model:1980)

  1. #1
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    Smile Restoring Yamaha 100cc (YB100, model:1980)

    Hi everyone,

    I have decided to restore my dad's old YB100. It has been lying around in the garage for 10 years or so. I would also like to mention that I have absolute ZERO experience regarding bikes or engines and not even remotely related to those, this is my first ever project.

    PS: Since I am a bit busy with my own projects, the progress on this is going to be a bit slow (probably only weekends). And this project can even fail due my lack of experience !


    OK enough talk, let's get started:

    Original condition: The bike appears to be in a pretty bad shape:

    Restoring Yamaha 100cc (YB100, model:1980) - 8685650134 9507a2cc25 b


    Special thanks: I would like to thank our respected pakwheels member @
    vickytulla (Waqar) for the much needed initial guidance.


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    one of my favorite D.I.Y thread
    nice work done
    waiting for more updates
    Love your Machine it reflects your personality

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    Week 3 updates (19-May-2013)

    Hi guys, hope all of you are doing great. This time I wasted entire weekend trying to open up totally deformed screws with little or no success. Attached pictures show the progress. Since I don't have much material this week, i've taken quite a few useless closeups and macros LOL . Enjoy !!!

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    Trying to remove the piston from the connecting rod:

    Restoring Yamaha 100cc (YB100, model:1980) - 8754428744 d974caa636 b

    First you need to remove both of the circlips retaining the gudgeon pin, also known as wrist pin or piston pin:

    Restoring Yamaha 100cc (YB100, model:1980) - 8754409476 38f31bfaaf b

    I used a nose plier to remove these circlips. Please note that these circlpis MUST NEVER be reused:

    Restoring Yamaha 100cc (YB100, model:1980) - 8753284689 938ef0b4e0 b

    Closeup:

    Restoring Yamaha 100cc (YB100, model:1980) - 8753284751 85709976e4 b

    nose plier closeup:

    Restoring Yamaha 100cc (YB100, model:1980) - 8753284717 3ecf97a391 b

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    But unfortunately the wrist pin is stuck inside the piston and is not coming out no matter how hard I try. I even used force (which I shouldn't have) and I think I made a tiny scratch on the piston as well . Well, i'll probably replace it if the condition is too bad.

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    Alright, FINALLY got the flywheel off. I must say it is a very powerful magnet: (As you can also see the piston wrist pin is stuck)

    Restoring Yamaha 100cc (YB100, model:1980) - 8754409342 2d319ac29e b

    Flywheel closeup:

    Restoring Yamaha 100cc (YB100, model:1980) - 8753284615 28c40e9da3 b

    A little more zoom:

    Restoring Yamaha 100cc (YB100, model:1980) - 8754409338 f30aed3bbd b

  7. #166
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    Flywheel from another angle. Now the magnet puller is totally stuck in the wheel LOL:

    Restoring Yamaha 100cc (YB100, model:1980) - 8753283923 4e912b024b b

    Little zoom:

    Restoring Yamaha 100cc (YB100, model:1980) - 8753283961 7ca250a242 b

    Further zoom:

    Restoring Yamaha 100cc (YB100, model:1980) - 8754408742 0bd55a9e80 b

    Restoring Yamaha 100cc (YB100, model:1980) - 8754408790 e9afc7f375 b

    Rusted surface on the wheel itself:

    Restoring Yamaha 100cc (YB100, model:1980) - 8753284113 e754809ae9 b

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    Closer look at the flywheel magnets. There are a few signs of wear and tear but I don't know whether I should replace the flywheel or not.

    Restoring Yamaha 100cc (YB100, model:1980) - 8753284353 82852ff816 b

    Closeup:

    Restoring Yamaha 100cc (YB100, model:1980) - 8753284379 1ba394388c b

    There is rust on the wheel components but not as bad as rest of the bike. Still clearing this will prove to be a nightmare:

    Restoring Yamaha 100cc (YB100, model:1980) - 8753284323 175075ed6d b

    The flywheel outer case also looks pretty beaten up. I wonder if would be able to reuse it:

    Restoring Yamaha 100cc (YB100, model:1980) - 8753284127 8e108ebf11 b

    Zooming in. Rust but not too serious:

    Restoring Yamaha 100cc (YB100, model:1980) - 8753284253 2d6f69d257 b

    Bit more zoom:

    Restoring Yamaha 100cc (YB100, model:1980) - 8753284217 55ce4d472f b

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    Now let's concentrate on the generator assembly:

    Restoring Yamaha 100cc (YB100, model:1980) - 8754408596 b63d7a5ee9 b

    Another angle:

    Restoring Yamaha 100cc (YB100, model:1980) - 8754409026 57a7540a67 b

    Yet another angle:

    Restoring Yamaha 100cc (YB100, model:1980) - 8753283629 aa1ff481e2 b

    Zooming in on the generator a little bit:

    Restoring Yamaha 100cc (YB100, model:1980) - 8753284587 f2b638b87b b

    Coil closeup:

    Restoring Yamaha 100cc (YB100, model:1980) - 8754409108 33c828ee27 b

    More zoom:

    Restoring Yamaha 100cc (YB100, model:1980) - 8753284559 0814d743ac b

  10. #169
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    Point system. We will look at it in great detail later on:

    Restoring Yamaha 100cc (YB100, model:1980) - 8753284473 1e047f7a57 b

    Some of the screws are in excellent condition:

    Restoring Yamaha 100cc (YB100, model:1980) - 8754409208 f6f0c4c443 b

    Some screws are in a horrible condition, thank you Mr. mechanic:

    Restoring Yamaha 100cc (YB100, model:1980) - 8753284543 9b303b01a9 b

  11. #170
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    Got drifted away LOL. Wooden plank closeup: (This is oak wood i guess)

    Restoring Yamaha 100cc (YB100, model:1980) - 8753283851 238d1a840f b

    Closeup:

    Restoring Yamaha 100cc (YB100, model:1980) - 8753284067 bcb266c124 b


    Okay, enough of the wooden plank closeups... Moving on...

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    Hitting brick wall (totally deformed screws):

    Ok so i've hit the brick wall. There are a few screws which are horribly deformed to such an extent that there is no way I might get them out without any physical damage to the casing:

    I first tried impact screw driver. But the screws were totally jammed, rust won this time. Since screws were already deformed and soft, impact screw driver probably damaged them a bit further:

    Restoring Yamaha 100cc (YB100, model:1980) - 8753283659 c65666a90e b

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    Then I applied WD-40 and left it there for around 7-8 hours. Then I used impact driver again, some of the screws came off with a bit of working around. But few screws got soft and further deformed due to the high torque impact driver. I also hammered the area surrounding the screws but failed to open them up (using a hard wood of course. DO NOT use metallic hammer on the case directly)

    Restoring Yamaha 100cc (YB100, model:1980) - 8754408092 629cb56360 b

    Closeup:

    Restoring Yamaha 100cc (YB100, model:1980) - 8754408158 9575c3c12b b

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    Some more damaged nightmare. Way too much rust and deformed screws, nuts and bolts. I mean:

    Give me a break. This is my first ever project !!!!!!!!!!


    Restoring Yamaha 100cc (YB100, model:1980) - 8753283727 f813479807 b


    Restoring Yamaha 100cc (YB100, model:1980) - 8754408160 7b86fb3a9f b

    Restoring Yamaha 100cc (YB100, model:1980) - 8753283515 2801a2b4d0 b

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    Concluding Week 3


    Ok people, this is it for the week. At this point I am totally stuck, I don't know how to get those screws off. Following are some strategies I had in mind:

    1) Heat areas surrounding the jammed screws using some kind of propane torch.

    2) After that apply loads of WD-40 in the expanded areas and leave it there for a day or two.

    3) Use a proper sized '-' or minus bit on the impact screw driver instead of '+' bit, drill a little bit '-' grooves and try minus impact driver again on the deformed screws.

    4) I am not sure about using the hammer and chisel technique but that is also one option, I mean what ever that gets the screws off of the engine.

    5) If still I can't get these open, I might have to borrow a drill from somewhere and try to drill out the deformed heads. That will hopefully detach the two engine blocks. In this case, will the front engine block come off easily while leaving screw shafts inside the other engine block? More work will have to be done to get the shafts out.

    6) I REALLY hate to say this, but last option: "Take the engine to the mechanic " (any good mechanic here in Lahore for this kind of stuff?)

    Question:
    If I apply option 5 (drilling the screws), what would be the worst case? Will I have to buy a new yamaha engine? If heads are drilled, I assumed that the shafts will still be in the casings, is it possible just to replace one of the case (other case should come right off as soon as screw heads are gone)?

    Edit: I forgot to mention that the piston wrist pin is also stuck!

    Thanks a lot for viewing. See you next week with more pictures and updates

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    Best of Luck.
    I Am the Feel
    I Am The Yamaha!

  17. #176
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    Quote Originally Posted by fakhir View Post
    Went to bilal ganj and bought some tools. The pressure gauge and impact screw driver are two very cool tools that I've ever owned:

    Restoring Yamaha 100cc (YB100, model:1980) - 8685649670 fe863ffe8b b

    Another angle of the bike:

    Restoring Yamaha 100cc (YB100, model:1980) - 8684532467 0454979369 b

    Yet another angle:

    Restoring Yamaha 100cc (YB100, model:1980) - 8685649880 f981bdbd64 b

    Looks like it was a heaven for spiders:

    Restoring Yamaha 100cc (YB100, model:1980) - 8685649860 da851e62aa b

    Restoring Yamaha 100cc (YB100, model:1980) - 8684532423 b59a921038 b
    Brother nice project but petrol of this yamaha maximum to 30km/litre
    would you like to share the price of whole toolkit showing in pictre without the pressure gauge please
    Suzuki jimny , Suzuki Cultus ,Suzuki Baleno

  18. #177
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    Very nic project but a little slow.

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    dump the tension ... and to open the screws which just brought you to halted position can be Opened easily and all you need is hammer-able (-) screw driver ... remember the screw head is soft so as you would hammer it on head screw driver will penetrate into the screw head now hammer it to Opening side (anti clock wise) don't worry that screw is getting damages because its expired already ... it will hope fully open or its head will chop away in both cases two engine blocks will be separated ...


    suppose screw head has chopped away and engine is open now you want to get the left half of screw out just take it to welder he will do the magic just ask him to get it out with damaging they know what to do ..

    Quote Originally Posted by fakhir View Post

    Concluding Week 3


    Ok people, this is it for the week. At this point I am totally stuck, I don't know how to get those screws off. Following are some strategies I had in mind:

    1) Heat areas surrounding the jammed screws using some kind of propane torch.

    2) After that apply loads of WD-40 in the expanded areas and leave it there for a day or two.

    3) Use a proper sized '-' or minus bit on the impact screw driver instead of '+' bit, drill a little bit '-' grooves and try minus impact driver again on the deformed screws.

    4) I am not sure about using the hammer and chisel technique but that is also one option, I mean what ever that gets the screws off of the engine.

    5) If still I can't get these open, I might have to borrow a drill from somewhere and try to drill out the deformed heads. That will hopefully detach the two engine blocks. In this case, will the front engine block come off easily while leaving screw shafts inside the other engine block? More work will have to be done to get the shafts out.

    6) I REALLY hate to say this, but last option: "Take the engine to the mechanic " (any good mechanic here in Lahore for this kind of stuff?)

    Question:
    If I apply option 5 (drilling the screws), what would be the worst case? Will I have to buy a new yamaha engine? If heads are drilled, I assumed that the shafts will still be in the casings, is it possible just to replace one of the case (other case should come right off as soon as screw heads are gone)?

    Edit: I forgot to mention that the piston wrist pin is also stuck!

    Thanks a lot for viewing. See you next week with more pictures and updates
    https://www.pakwheels.com/forums/motorcycle-travel-diaries/277725-sober-riders-visit-khunjerab-adventurous-way-via-nori-pass

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    Hopefully this technique will work
    Once I broke the head of a Bolt and lathe man do that trick, he drilled a hole in the broken bot and then put a another long bolt and then opened that broken bolt ...

    Quote Originally Posted by vickytulla View Post
    dump the tension ... and to open the screws which just brought you to halted position can be Opened easily and all you need is hammer-able (-) screw driver ... remember the screw head is soft so as you would hammer it on head screw driver will penetrate into the screw head now hammer it to Opening side (anti clock wise) don't worry that screw is getting damages because its expired already ... it will hope fully open or its head will chop away in both cases two engine blocks will be separated ...


    suppose screw head has chopped away and engine is open now you want to get the left half of screw out just take it to welder he will do the magic just ask him to get it out with damaging they know what to do ..

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    Quote Originally Posted by vickytulla View Post
    dump the tension ... and to open the screws which just brought you to halted position can be Opened easily and all you need is hammer-able (-) screw driver ... remember the screw head is soft so as you would hammer it on head screw driver will penetrate into the screw head now hammer it to Opening side (anti clock wise) don't worry that screw is getting damages because its expired already ... it will hope fully open or its head will chop away in both cases two engine blocks will be separated ...


    suppose screw head has chopped away and engine is open now you want to get the left half of screw out just take it to welder he will do the magic just ask him to get it out with damaging they know what to do ..
    Yup i have tried this method before it works but u have to make sure that the screw driver has penetrated enough that i won,t slip again all u need is to make a cut in the bolt u can do it with hammer and screw driver or small drilling machine like this
    Restoring Yamaha 100cc YB100 model1980 -1189220
    it u can work with it easily with different angles and it comes with a lot of tools and can make a cut in any bolt so that screw driver can fit in easily
    But try not to buy pink one
    Can,t think of a better signature

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