Restoration of my classic Yamahas: Made parts using precision machining

Machining parts for the RD 200 is something that is not new and we have made quite a few parts in house.

BHPian SnS_12 recently shared this with other enthusiasts:

Precision Machining:

To maintain such a big collection of rare motorcycles is only possible when you have someone extremely knowledgeable to work and maintain them. And when that person is a perfectionist just like you it can create wonders like none other. I had mentioned that I was having difficulties in finding the fins that fit on the RD 200 panels. When I mentioned this to Tony and while we were brainstorming on what is the next best alternative he came up with the idea of making a set in aluminium. Machining parts for the RD 200 is something that is not new and we have made quite a few parts in house. But this needed precision on a next level because we wanted to recreate the same design as the original has and the measurements had to be perfect for to it have a perfect seat. Tony as usual worked out his magic and the finished product is nothing short of being magical to see and hold in your hands.

Now, we will have to get the curvature correct before the piece can be sent for painting along with the RD 125 parts. Further, I went ahead and ordered a pair of kick springs to be used on the RD 200 and a kick from Ebay along with a tacho cable each for the RD 200 and RD 125 and and throttle cable for the RD 125. Since, I had no one coming down from UK immediately I couldn’t order from Yambits and had to rely on Ebay instead. Kick springs are arriving from Thailand and cables and the kick from Germany..Now, you can understand why maintaining a track of cost for such rebuilds never make sense as it can never give you a true picture of what sort of budget one has to expect other than knowing that it is going to turn out to be very very expensive…

Some pictures…

The original seat of the RD 125 and the half broken rear seat cowl. The seat lock mechanism is similar to the RXZ and now have to figure out if someone can make a same seat plate and repair the rear seat cowl as well

The seat lock similar to the RXZ

Fins for the RD 200 made out of aluminium and machined to perfection on a milling machine

What a perfect seat

Will have to bend them slightly for a perfect seat

Planning to paint the fins in same titanium grey shade as the fork legs. So, now with addition of the fins and once the kick and kick spring arrives the internal can be changed back to OE with the OE kick and new clutch cover

Kick spring for the baby RD’s arriving from Thailand

OE kick for the RD 200 arriving from Germany

OE tacho cable for the RD 200 as the one we have on the bike currently is a bit too long

Back tyre finalised for the RD 125. Had to settle with Apollos as Michelin were out of stock with no confirmation when a set would be available next

Front tyre

Throttle cable for the RD 125

Tacho cable for the RD 125. Since the 125 is a DX edition the bottom end of the cable is different from the RD 200.

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