Yamaha IT175K

[BBR]

Popped the crank seals out and pulled the wheels off.

Seals were hard and cracked so it's good that I decided to replace them. New ones should be here tomorrow. I cleaned all the goo out of the case on this side. It cleaned up nice.

Front wheel bearings are usable, but squeaky, so I will replace them. Brake shoes are completely worn out.

Rear wheel bearings are toast. Rear brake shoes aren't too bad. Might just clean them up. Took some work to get the rear axle out. It was stuck to the spacer that is inside the hub. I had to drive it out with a brass drift.

[Captain]

Watching this ......
Ya NEVER KNOW what could end up in your shop.
I'm to be in the Twelve Step Program and
Not Drag Anymore Rusty Orphan's Home.
But I swear, Friends and Neighbors wait until
you leave for a few days, and "Stuff" ends up in front of your shop doors. They don't have the heart or are too cheap to haul it off to the Dump themselves!!

Plus, my two sons have told me that I can ONLY GET 2 MORE Scooters.......
Then I will have one for Every Day of the Week!!

[BBR]

I try not to drag home too many strays!

Engine seals arrived Saturday, tires will be here today, chain & sprockets tomorrow.

I ordered more stuff I need for the brakes/wheels/forks. Brake shoes, fork seals, wheel bearings, fork boots. Parts are surprisingly cheap for these things.

[BBR]

Today, I took two carbs and made one presumably good carb.

[DanStokes]

Good luck! I never did well with small engine carbs.

[BBR]

Waiting on parts is driving me crazy. I keep taking more stuff apart!

Pulled the forks off and managed to hork up one of the fork caps. Great. Funny thing is, I can buy a whole set of forks for just a little more than what people want for a single cap. Haha.

[BBR]

The forks are starting to tick me off.

One cap is completely jacked. I am not sure how I'm going to get it out. Then I totally smoked my pinkie with a hammer trying to get the seals out of one of them.

I was hoping to not have to disassemble them, but I can't get the seals out without taking them apart. They are stuuuuuuck in there.

The next problem is the damper rod requires a holding tool to keep them from spinning when loosening the bottom bolt. I don't have one. I think I can make one though.

[BBR]

Fork torture may be coming to an end. I finally got them apart!!!

[BBR]

Looks like Monday will be the heyday for parts to arrive. Wheel bearings and air filter basket arrived today.

I was looking at fork seal drivers last night then remembered I have a 3d printer, therefore I can literally make anything I need. I designed one this morning and it is currently printing.

Since a full set of 1982 yz125 forks (darn near exactly like these) was only $51 and people wanted $40 for ONE fork cap, I just bought the forks. I only need one cap off of them, but it'll be nice to have them for parts should the need arise.

[BBR]

I poked the new wheel bearings in, made a new tool to hold the damper rods and put new seals on the counter shaft and the shift shaft.

The chain side rear wheel bearing's bore is a little wallered so the bearing does not fit snugly. I put some red loctite on it and tomorrow I will take my center punch and stake the edges to try and lock it in place a little better.


Pic of destroyed fork cap and the disassembled forks!

[BBR]

Put the forks back together, cleaned a bunch more, put the new brake shoes in the front and popped in one of the crank seals.

The 3d printed seal driver I made worked fantastic.

[BBR]

"New" clutch basket showed up from Canada. Much much nicer than the one I took out!

Actually a lot of things showed up. O-ring, clutch plates, clutch basket & rear brake shoes!

The company I ordered the gaskets from is really dragging their feet. I don't know what the problem with them is....

[Captain]

LOL,
You are going to end up with a NEW BIKE...
So far, you have only saved the Gas Tank, Frame, and the Covers for the Engine.....

But who am I to Throw Stones !!
Let me dig thru my Scooter Parts Boxes.
At one time I had 2 donor Yamaha's hanging out in the barns......
I will Post any treasures I find.

[BBR]

Popped the crank seal in and installed the clutch. Sorta. I forgot to put a small seal retainer in place so it ended up having to take it all back apart. Haha.

Forks also showed up today. They are actually 1982 YZ125 forks, which I knew. They are 38 mm KYB forks just like the IT forks, so I figured the caps would be very similar. Nope The YZ caps are taller than IT caps. So if you try to use a YZ cap in the IT fork tube it runs out of thread before the cap seats properly.

Since they are both 38 mm forks I'm just going to run the YZ forks on the IT they have one more inch of travel, but I don't think that's going to be a an issue.

[DanStokes]

So the same only different.