1978 1T5 Yamaha XS750 from Poland - repair, rebuild and fun log.

[eMCZe]

Hi,

I'm new user from Poland. I bought XS750 and decided to rebuild it for me. I do it for fun from ride and fun from build.
I often read the forum out of curiosity, but now I decided to put your knowledge into practice in my own garage.

Here's the patient, a 1978 Yamaha XS750, bought already in the process of converting to a scrambler...

... when I saw this naked frame I love it and pack it to my truck ...

I bought not only frame with body but with all parts and even more...

At home, took out XS from truck, look at my new love...

... and decided to change the previous owner's plan and that's why I'm here.


Greetings to everyone at DTT,

Marcin

 

[eMCZe]

I forgot about my plans for Yamaha... yes it will be kind of cafe racer

All mechanical parts goes to my friend, he should rebuilt engine and gearbox ( I have original one with matching numbers for parts and second one working ).

I will do all body works, electrical works and other.

Here is the scope of work I have imagined:
- change tires
- clean from the rust and protect the tank
- rebuilt body from tourist to racer
- paint body
- change whole electric to mo.unit
- change front brake system
- change "dashboard"
- rebuilt engine
and more what will born in my head.

Some of the work is already underway, some is already done, and some is still in the planning stages. I hope you enjoy photos and lengthy posts, because that's just how I am.

Regards,
Marcin

 

[Rider52]

Welcome!

 

[eMCZe]

I started from tank. Inside was little bit rusty...

First, I rinsed everything with water under pressure and then I poured rust remover over the entire tank overnight. The next day the magic will happen.

Then I filled the tank with resin for tank preservation and repair.

a few days of drying, the fuel tank is ready for another 50 years of life.

 

[eMCZe]

Last thing about tank repair. Here it is after a week when the epoxy has completely dried.

I used a system from the German company Fertan. Fedox rust remover and Tapox 2K epoxy resin.

"Tapox 2K coating lasts for many years and, in most cases, provides lifetime protection for the tank. Since it is a hard, chemically cured epoxy resin, once fully dried, it becomes an integral part of the tank and does not undergo biodegradation or dissolution by fuels."

It's important to note from my observation, that if you want to use this, it should be done only before preparing and repainting the tank. The resin is so dense that removing it from the tank is almost impossible without staining the surface.

 

[ridesolo]

Good looking start! That should be a nice bike.

 

[eMCZe]

Good looking start! That should be a nice bike.

Thank you very much... and I hope.

Before I post more about tank few words about engine.

Previous owner bought XS fully working, maybe not perfect but working. When I bought from him engine was removed and open. It good reason to overhaull it.

First we checked both cylinder blocks and cylinder heads and we chose the better ones

measured cylinder liners and were almost 0,1 mm more than new, I decide to buy new +0,25 pistons and pistons rings set.

tomorrow engine parts goes to sand blasting, after that to the workshop, which will grind the sleeves for new pistons and renew the cylinder head.

In the meantime, my engine guy will check what else can be used from this

and what needs to be ordered new

 

[eMCZe]

Dash... XS has standard like most 70/80 bike. Two clock with lamp panel beetwen.

I want to change it, one central speedo and below one digital bar with tacho and indicator. I started by disassembling it into parts.

Because speedo metal ring was bend I used ring from tacho and polished it.

I cut double clock bracket and transformed it into one central and welded with speedo cup.

when new dash bracket goes to powder painting I order new foam for clock, old was completely degraded.

 

[eMCZe]

Time for daily dose of my XS... If I write or rather post too many photos, please let me know.

My custom speedo back from paint shop with new powder coat

I like it.

 

[ridesolo]

Nicely done!

Time for daily dose of my XS... If I write or rather post too many photos, please let me know.

There's probably no such thing as too many photos on DTT!

 

[eMCZe]

There's probably no such thing as too many photos on DTT!

you shouldn't say that - I checked my disk drive and I have over 1000 photos from work on XS I bought it 2 months ago
I've already done a lot of work, but I'm presenting it in small pieces so that it will last longer.

 

[eMCZe]

News from now. Today efore cylinders head goes to glass blasting was disassembled and the intake channels were aligned.

 

[eMCZe]

Back to fuel tank...

Yama was green but before, from new... who knows??
I started removing paint and

almost like a rainbow

I thought about just applying clearcoat and leaving it at that.

but I wasn't sure what was underneath, so I removed everything. That's good, because there were dents under the paint. On right top

and right side

rest of surface was in good condition

I started repairing it and preparing it for painting.

 

[ridesolo]

I can understand thinking about just clear coating over what you had. That really wasn't bad looking. I am sure you made the right choice, though.

 

[eMCZe]

I am sure you made the right choice, though.

As you could see, I cleaned everything down to the bare metal.

One of the reason was my helmet. I have Hedon Heroin Racer White Knight and I decide to go this direction.

I almost finish work and you will see soon.