YDS3 project

This is about as rough as they come but it did actually run. The bike is a 250cc twin cylinder two stroke.
It is a 1966 model and was bought on the cheap ($300)

This is what it should look like.

After a complete disassembly the parts were bead blasted to bare metal by Phil Osterkamp 
(251) 865 3678 in Grand Bay, AL and painted.

The dents were taken care of and the parts were primed. 

Paint was base coat/clear coat automotive paint. The red was a PT cruiser color.  This paint is 
easy to use. It is run-resistant and a couple coats of clear over the flat colored base coat gives 
a deep shine. Be sure to use the polyurethane hardener in the clear.

Forks go on first just so it starts to look like a motorcycle.

Put on the rear wheel and it is on its feet.

The wiring is next.  I wonder where that yellow wire went?  Note the new sprocket.  The rims and 
spokes are the ones that were on the bike after a good wash with a Brillo pad. The original 
chrome from Japan still look good after 46 years of abuse.  I have not replated anything yet 
although the chain guard came off another bike. The aluminum parts were buffed and polished.  

Drop the motor in before putting those heavy iron cylinders back on.  The pistons and bores 
looked good as did the bottom end. I did replace the right crankshaft seal while I was in there.

The clutch is on the left end of the crankshaft (weird),  Little did I know that the previous owner only put 3
of the 5 clutch plates in which caused a very light preload on the clutch springs.  It slipped like crazy on the
first test ride.  A set of new plates fixed that. Notice the plastic oil lines that inject oil into the intake 
manifolds. There is no primary chain to get out of adjustment - just gears from the crank to the tranny. 
The oil pump runs off the big transmission gear.  When you are sitting in first gear at a stoplight the oil 
pump  is not turning.  If its a long light you better put it in neutral and let out the clutch (weird again).

Here the oil pump is installed, as is the air cleaner. The chrome fenders were beyond re plating 
so the dents were fixed with Bondo and painted Toyota silver base coat/clear coat.  They 
actually look pretty good. I used the same paint for the engine covers. Do to use spray can paint
on the engine as it will wash off the first time gasoline drips on it.  The oil pump had a small 
crack in it which leaked oil. Epoxy didn't fix it and I finally had to replace the pump body.

These oil tank decals are always available on eBay

Ready for the seat and tank.  I found some so-so header pipes on eBay.  The mufflers are what was on the
bike and need replating. Fortunately they are not dented or too badly pitted.  The plating will have to wait for 
phase 2.  The front fender is from a Yamaha DS6 (1970) which has slightly different braces than the YDS3.

I had a good seat pan and found a new foam pad and seat cover on eBay which fit perfectly.
The original tank badges were beyond repair but a set of repos were found on eBay. Ready 
for a ride.

Runs good.  Cruises at 60 mph at 4500 rpm in 5th gear. Note the new Bridgestone front tire.

The generator cover had really bad chrome (not rusty, just worn off). Since this picture I found a
nice one on eBay. I bought it cheap and it was the first time that the actual part looked better
than the picture. Pretty good but the pipes had some serious rust on them which kills the whole 
effect so...

...the mufflers and headers were sent to Precision Metal here in Mobile for plating and for $200
they now look like new.

 I traded the bike for a 1970 BSA in 2012 but got it back in 2019. It got a new rear tire, some
new chrome hardware including the handlebars and a correct front fender that I found at
Barber's. It was suffering from typical ethanol-containing gas damage so I had to clean and line
the tank with Red Coat and rebuild the carbs. Now it runs as good as ever.