After spending so much time filing, sawing, and drilling rusted bolts out of their sockets, I decided not to prioritise originality over expediency, and invested in some stainless steel equivalents.
Finding the original bolt sizes was surprisingly easy, as the thread diameter and length are baked into the original yamaha part numbers.
Decoding Yamaha Part numbers.
For example…
97306-08016 = 8mm thread, 16mm long
92502-06016 = 6mm thread, 16mm long
Much more cleaning, de-rusting, and painting and then bolting stuff to the rolling chassis.
So a couple of quick observations on the photos above.
1. that horn is clearly too big for the mount and placement.
when attempting to put the headlamp shell in place, it was clear that there would be insufficient clearance to tilt it down to shine on the road.
A little research showed it, at 100mm diameter, to be too big even for one of a 350 pairing, (which are apparently 90mm).
It is hard to find exactly what a 250 horn should look like or what size it should be, so I have purchased a little 70mm generic horn, which will hopefully sit happily behind the headlamp shell.
2. that nice clean coil has had its connector butchered and replaced with spade connectors.
It’s time for another visit to the Parts-Box, where I am sure I have seen another.
Now its time to fit the rear subframe, and… DISASTER!
The rear sub-frame is too wide!
On further investigation, and after comparing to my running everyday LC, it appears that rather, it is the other way around, and the rear frame rails are too narrow.
Somewhere, at some time, the back of the frame has been clamped and squeezed together by a couple of centimeters.
I can only imagine that this happened when the frame was off for repair, as I dont have any tooling which could do this.
The question now than, is how do I reverse the squeezing, and return the frame rails to their correct placement.
First, all the stuff I had already bolted on had to be removed, then this…
Yes. A jack!
By extending the frame rails slightly further than necessary, and releasing, I hope to adjust the spread so that the rear-subframe, and the seat, will line up and fit.