Roadstar Bobber

[Luky]

This is a new build.
I started by buying a engine from Ebay.
Be careful what you buy!! What I mean is make sure parts are not missing.
Every missing item could be $10.-$50.


The engine weighs 250lbs., without the middle drive/oil reservoir.
I needed to get the engine up on my build table. I did not have a hydraulic lift table.
Here is what I did. I scootched the engine off of the pallet onto the table.

Click on photo for a larger version.
I moved the engine by hand then I would jack the other end of the table up and attach legs.

(to be continued)

[Luky]

WE (My wife and lovely assistant and I) got the build table level. About two hours work.
Glad its over! The engine is a 2004 Roadstar engine with 37,000 miles.



to be continued....

[TriNortchopz]

"to be continued...." that looks like a better way than liftin' it up on the bench.
What is your vision for this build?

[Luky]

"to be continued...." that looks like a better way than liftin' it up on the bench.
What is your vision for this build?

We got the end of the bench about halfway up then I attached some legs in the middle of the bench for safety. We moved the engine towards the other end of the bench and it was much easier to jack up.
My vision is sort of like...

Click on photo for a larger version.

[TriNortchopz]

That's a great vision for your build - if you can turn that yammie into a knuck, I'm definitely subscribing!LOL.
Oh, and I would add a vertical piece of 2x4 between the upper and lower rails next to the uprights on your bench if you haven't done it already...

[Luky]

"Add another 2x4 between rails." The shear strength of a single 16 penny nail is 1100LBs.!

[Luky]

I spent some time removing that murderous black spray paint that was on some chrome engine parts.
I like the look that has some bling sprinkled around.


You can click on the photo to get a larger picture.

[Luky]

I ordered a sprocket for the engine countershaft(right side drive).
It is from Pro Tek #551 for Yamaha MT-01 (same as Roadstar). It fit perfectly.
It is stainless ,probably 400 series.

On a previous build that was the same except left side drive like a stock
Yamaha Roadstar, I got a Yamaha R1 sprocket #556 from
Sprocket Specialists. It was steel. Either sprocket will work.

Either sprocket will fit the countershaft left or right side of the engine(same shaft size).
I like this sprocket with the holes in it.

Photo right side drive from the countershaft.


This Yamaha V twin does not need the (middle drive) gear box/oil tank.
It is a hollow aluminum box with a shaft running through it from the right side of the engine to the left side of the engine. The purpose of this was to lower the speed of the output shaft so that the belts would last longer. It also holds 2 extra quarts of oil for the engine. The total oil supply for the engine is 4 quarts. So it is a partly dry sump oil system.

[Luky]

Things I have done this week.

I installed a Adjustable thumbscrew Air pilot screw to this carb.
I had to carefully straighten out the hole it went in because someone had buggered it up.
Click on photo for larger version.

I also installed two AIS (Air Injection System) block off plates on the engine cylinders.

Installed a new cam case outer cover that the salvage yard busted,or was damaged in an accident.

Installed a new clutch disengagement arm and spring that the salvage yard lost from the engine.

Next is new jetting and slide needle for the stock carb for "stage 2" configured intake and exhaust.

[Luky]

The rear wheel arrived today. Yeaaah!!!
60 spoke chrome wheel. tubeless style.

16 x 5.5" 3/4 axle.

[Luky]

To sum up so far.
I have the engine.
I built a build table.
I have two wheels with tires mounted.
I had trouble mounting one tire and the solution
was to put the tire and wheel out in the sun and that
made getting the tire on completely easy.
I also have a wiring harness.
I have the engine mounting bolts.

[forty4ma9]

Nice project; looking forward to seeing more.

I have often thought the roadstars have good looking motors. I always like seeing them built into cool things and you have some good inspiration bikes shown.

[Luky]

Nice project; looking forward to seeing more.

I have often thought the roadstars have good looking motors. I always like seeing them built into cool things and you have some good inspiration bikes shown.

Yes.... forty4ma9 I agree that the Yamaha Roadstar engine is a great looking engine for a custom bike.

[Luky]

Both wheels with tires mounted.
Both wheels 60 spoke.
Big investment,but worth it.
Rear is 200mm x 16 x 5.5, Radial, tubeless.
Front is 21" x 2.15 rim, Bias ply, tubeless.
Both tires Avon Cobra. Avon said this was ok .
Both tires are V rated.

[Spelkbot]

Looking good!
I have 3 Roadstars right now, 2000 I fixed from a slow speed lowside, 2003 bobber project & 2006 I refer to as 'the pretty bike'.

Roadstar engines not only look tough, they're insanely tough inside. Possibly the best engineered pushrod twin ever made.