How was the fit of the mag side crank in the bearing?

Tight. In fact when it was all together there was no play what-so-ever on either side. If it wasn't for the howling noise of the bearings you would have never known there was an issue. Even the bearings had no movement. This engine was dry everywhere. Not a drop of oil in the crank cavity, bearings or the engine cases. None! I didn't even see much sealant if any in some area's of the center cases. Usually there stuck together pretty good. this one wasn't. 

There was also 2 shims on the mag side and 1 shim on the pump side but the crank rotated freely. Never seen 2 shims on a mag side before. Will have to do some measurement when it goes back together and see what's going on. Have not measured the shim sizes or the crank width yet.

I know this bike was restored as a show bike. He may have just slapped the engine together just to look good. There was shims out of place, wrong circlips and things loose everywhere along with the bad teeth on the gears and gouges on the clutch basket. Never seen anything like it. But I'm not surprised either.

It will be an interesting build for sure. looking forward to it.

So I press the crank apart this morning to inspect. This is what i found.
All was good but the rod. So now it's getting the whole kit and kaboodal. 

I was lucky and found a NOS rod on e-bay 30 miles from me. Will be replacing the bearing, pin and washers too. 
What else is going to come up? 







 

Bummer it was bad.  But a lot better to catch it now rather than in a few months!

I have a feeling it's going to be smooth sailing the rest of the way.  

Finally received my stuff back from Bill Bune Enterprises. They were on vacation all last week. UPS arrived about 11am today.  Went right to work and reassembled the CT1-175 engine today. Will get it into the frame tomorrow and with a little luck, have it running this weekend.  

Complete engine rebuild. All new engine bearings, seals, gaskets, rebuilt crankshaft with all Yamaha oem parts. Complete new top end. New Yamaha clutch plates, heavy duty springs, new kick gear and idler gear, modified the kick gear spring so it's works better. Replaced clutch basket, replaced springs on stopper lever assy and shift shaft assy. Adjusted shift shaft. rebuilt the oil pump. All new oil lines and clamps, new condenser (points look great) set timing. ordered a new magneto harness rubber grommet from KDI. this one was missing. Of course complete carburetor rebuild using only Yamaha or Mikuni parts.

Nice to get this mess off my work bench. 



New crank rebuild ready to install.



Crank and gear set installed in left side center case.





All assembled before clutch goes on. 



Last check before right side cover goes on. Make sure shim spacers are in place on kick shaft and tach drive. 



Setting timing on engine. Was able to get it to 1.76mm. Also aligned timing pointer right at 1.8mm so head doesn't have to be removed next time. 





Finished engine ready to install in frame. Not much to these small bore engines. No parts left over so i guess that's a good thing. Lets hope it runs as good as it went together.








 

Nice pic lay out.   Lmao at shim comment on tach.  I said
same about mine.  

engine looks real good.  Looking forward to hearing it run.  

 

Thanks PABDT,

Will post some pictures of the bike tonight. Running video coming soon. Got it started today. Runs super nice. 

Ok, the 4th and last bike is done


This bike I knew was going to be the hardest and most expensive to bring back to life just by looking at it when i bought the 4 bikes. Little did i know it was as bad as it was. This was definitely a lipstick on a pig motorcycle. It even fooled me as i didn't have a lot of time to look it over good when i went to pick the bikes up. But that's ok, It's was a good challenge for me as i have not worked on a CT1 in many years. 

Of coarse the engine had to be completely rebuilt as you can see by now. Had to completely go thru all the wiring and connect, repair and reroute everything. Nothing was connected. He even had different color wires inside the grey sleeves so i had to go thru every wire and make it right. I even bought a good used harness but ended up not using it. The battery box was mounted in backwards making the rectifier in the wrong place so the wires would not reach it. fixed that. Had to repair the light socket in the tail light. replace all the rubber grommets and rubber bracket mount. 

Bike had a AT1 front fender on it. I was lucky and found the correct aluminum front fender and mounts for the bike. Just had to repaint it. Also it had some cheap Chinese rear shocks on it. Again was lucky and found the correct original shocks. Had to restore them and shine them up. Next was the handlebars. again wrong ones. Replace them too. Next was the fork caps. It had the caps off the newer bikes (small) like on a CT3. You couldn't even remove the fork caps without removing the forks out of the triple clamps! So had to buy the correct older large fork caps. I flushed out the oil tank and gas tank. They were full of dust as this bike hasn't run in who knows how many years. It was for show only. I put all new bulbs in the gauges and high beam indicator and rear tail light. Had Deet restore the mangle up left horn switch. Had to replace the horn itself. 
I went ahead and put new tires, tubes and rim strips on the bike. Had originals on it but they were weather cracked pretty bad. I sure wish someone would make a 3.25-18 trials tire for these bikes. Had to install 3.50-18 Shinko 241's front and back. 3.00-18 is just to small on the CT1. looks ok on the AT1 because of the different fender. 
Bike does have new rims, new spoke sets, all new wheel bearings and new brake shoes so didn't have to do any of that. The rear axle nut is wrong. I have the correct one coming. In fact many of the bolts and screws were wrong on the bike. Replaced so many of them. Recondition the original seat. I was able to save the original cover and foam. I just had to repaint the YAMAHA logo on the back of the seat. Also inserted a thin foam layer thru the breather holes so the old crumbling foam wont come out and get all over the bike. Padding is still nice and firm. 

Installed a new battery and strap. New updated K&L fuel petcock. It's the same as the latest replacement Yamaha OEM petcock. Actually these petcocks work better then the original Yamaha petcocks. Has a new air filter in it and i replaced the rubber intake boot from airbox to carb. Both are from KDI. All new hoses and clamps for fuel and oil injection. Have to replace the rear brake light switch. it snaped in half on me when i tried to hand tighten it. Had to re-connect the front switch. It wasn't even in the correct pin. lubed and adjusted all the cables. Greased the swingarm pivot and both axles.

Installed the engine, connected the chain and cables. bleed the oil pump and put some non-ethanol gas in it and she started 2nd kick. Did 2 heat cycles and then a short test ride. Engine is outstanding. Runs very strong, jetted perfect. No top end rattle what-so-ever. Nice and tight. Trans shifts perfect. clutch works great, smooth, no slippage. engine Idles great. Looking forward to riding this bike more. Much stronger then the 69 AT1. Still have to do something with the pipe. don't like the looks of it. Wish i could find a nice clean aftermarket pipe. Or maybe even a nice stock pipe. This one doesn't have any dents but does have some pitting above the chrome heat guard and at the curve bend.  I may be able to smooth them out and repaint. It's also a sleeper pipe. Sounds good that's for sure. 

The next few weeks will be the time for fixing all the little things that will pop up and get some mileage on her. So far I'm very impressed with it. It's a good looking bike. Powder coated frame, New wheel sets, very nice paint on the body parts. Chromes decent. The 175's were never my cup of tea but i must admit its a fun bike to ride. Light and powerful. 

I will get a running video posted once i finish up the small stuff and do something with the pipe.   






Had to repaint the YAMAHA on the original seat



Nice looking color on the 69 CT1.



Riders view




Strong running engine the 175 is:





 

I was able to get the pipe looking pretty good today. Used one of those flap sanding disc and about 2 hours time. then wet sanded and repainted.  This pipe was pitted all across the top above the steel guard and on the header pipe. It was really bad, Look like crap! Got about 95% of it gone. I am glad because this is a sleeper pipe and i wanted to keep it on the bike. 

I think i will swap pipes from the AT1 and see how both bikes respond to the different pipes. This will tell me a lot about the stock pipe on the AT1. 









 

 

I like your workbench setup. What kind of metal trays are those?

My wife got new cookie sheets for Christmas, so I have been using the old ones she was tossing out, but they are much smaller than the ones I see on your bench.