Time Needed

Time is a huge variable. Skill and familiarity usually means speedy. For example: an experienced mechanic, building a 108ci (or PR 110ci) engine, could do the entire project in a weekend or less--assuming they had all parts available. As another example, the Road Star transmission recall, which involved splitting the cases, was done by Yamaha mechanics in only eight hours--give or take.

By contrast, I took nearly five months to do a complete build--a few hours at a time. My tear-down was more complete than either example above. I was also unfamiliar with the engine details. Your project will likely be more than a weekend, but less than five months.

On average, I devoted one full day per week. I also put in an hour here and there after work, each week. Basically, my time breakdown was like this:

• 30 days -- To order and receive my parts. I was reluctant to start until I had my parts in hand.
• 10 days -- To tear the engine down, including labeling and storing parts.
• 7 days -- Waiting for my Yamaha dealer to remove transmission (and transfer case) bearings.
• 14 days -- For the machinist to do all the initial machining work on the heads, cylinders and crankcases.
• 7 days -- To box up engine cases and take/send to DK Powdercoating. This was mostly due to my work schedule.
• 14 days -- For powdercoating.
• 14 days -- For me to do custom details like head-port smoothing and cooling-fin tip polishing.
• 21 days -- For the machinist to finish machining (valve job, honing cylinders). He was back-logged.
• 30 days -- To reassemble everything, taking my time to feel sure about getting everything right--checking, photographing, and rechecking each subassembly. This also included fitting my new carb to the bike and fabricating a new way to attach it to my air cleaner.
• 7 days -- To get it running well enough to ride to work with confidence that I wouldn't get stranded.

It adds up fast.

Deciphering Yamaha Part Numbers for Bolts

The information below can be learned, from within the part numbers for Yamaha bolts--with many exceptions to the rule. The first five digits may indicate what type of head the bolt has--flange, straight, button, etc--as well as hardness. However, there are so many exceptions, this information is not reliable. The center five digits of the part number are usually (but not always) as follows:

• Digits 6 - 7 are usually the bolt diameter (in mm)
• Digits 8 - 10 are usually the bolt length (in mm)

You can use this information in searching for the correct part number to purchase, or for verifying which bolt is to be reinstalled where.

Service Manual Errors

• Pg: 2-34 of the 1600 Road Star manual. Item #17 is shown routing to left side of engine. It actually goes to right side.
• Rear axle torque is way too much. The torque should be around 65 to 85 ft-lbs.

Proceeding to the Next Step

To access related articles, refer back to the Complete Engine Tear Down, Orientation article in this series to see which additional article(s) best addresses your situation.

Questions should be asked in our forum (Use discuss link below). The forum is very active and you stand a good chance of getting your questions answered there. If you would like to leave feedback for the author, or have additional information you think will benefit others, please use the comment section at the bottom of this page.

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DISCLAIMER: This information and procedure is provided as a courtesy and is for informational purposes only.  Neither the publishers nor the authors accept any responsibility for the accuracy, applicability, or suitability of this procedure.  You assume all risks associated with the use of this information.  NEITHER THE PUBLISHERs NOR THE AUTHORs SHALL IN ANY EVENT BE LIABLE FOR ANY DIRECT, INDIRECT, PUNITIVE, SPECIAL, INCIDENTAL, OR CONSEQUENTIAL DAMAGES, OF ANY NATURE ARISING OUT OF OR IN ANY WAY CONNECTED WITH THE USE OR MISUSE OF THIS INFORMATION OR LACK OF INFORMATION.  Any type of modification or service work on your motorcycle should always be performed by a professional mechanic. If performed incorrectly, this procedure may endanger the safety of you and others on your motorcycle and possibly invalidate your manufacturer’s warranty.

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