Motorcycle Frame Assembly

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We assemble our motorcycle frame with the swingarm, steering stem, forks, and suspension components for our Yamaha TTR225 Project. This bike is the motorcycle that we are using in our wheelie bike project.
Being over fifty and never mastering the wheelie, this is the motorcycle that we are going to try and learn with. Hopefully we wont be videoing any hospitals rooms
TRANSCRIPT:
I have kind of laid out everything.
One of the things that we haven't talk about. Is when ever I am working on something, generally I will go out and I will take a micro-fiche and I will print it off and I will study it.
Two reasons for doing this One it will help you identify parts or part numbers that you may need to order and have on hand before the reassembly. Two you do not always know that the previous owner who put the bike together last, if it is not from the factory, did it with the right fasteners with the right pieces, or in the right sequence.
It is always good to have one of these to compare to. And this came this way.
Looking at the micro-fiche that is coming from that side right there
Perfect
We will get this up and we will tighten all the bolts and make the grease and fittings. and everything once we get
That is better Did not have the replacement seal, for this needle bearing. But, now I need to get grease in these bearings. So what I am going to do is pack it from the top.
And we use the same pressure we would as we had it cupped in our hand earlier. We will just use that same pressure to force a little bit at a time down into the bearing.
Forcing the grease down through the small gap. between the inter and outer race. Ok I can see it coming out the bottom
We have actually forced enough in through the gaps in the bearing the cage down through the needle bearings.
And I can see it come up out of the bottom So I know that the bearing is fully lubricated and greased. we will spin to make sure that we can see the grease changing directions and we do we see it dragging.
We are going to replace the balls there are 22 ball bearings that run on this race. To hold those in place we are just going to use a little bit of grease.
What we will do here Grease that needs to be there anyway. It is very important that we do not lose any of these. What I did is that I cleaned them yesterday.
The grease will lubricate the balls, and will be there permanently But, right now the idea is that it will hold our bearings. The balls in place. The grease is holding the twenty-two of them. You can see that there is no unusual gaps or anything around the circle around the circumference
This is the reverse of that race. This also has a rounded surface. That will fit down on top of there. Put a little grease on this. Don't need a lot just need enough there to hold it.
Alright That completes the bearing.
This is our triple clamp assembly. This is our steering head steering stem Again the needle bearings greased ready to go. The race is already installed in the bottom. We are just going to come up through here. And carefully come through that. To that we cap off, we got a seal and dust cover.
And to that this is actually what we'll use to adjust the tension of the forks Just from experience what I'm going to do I'm going to tighten this up.
This is a spanner wrench I'm going to tighten it up and turn it I want to make sure the bearing seat and all the grease has worked in there and This is a little bit tight because I can feel it loosen and tighten.
Alright I don't want any play. That has a good solid feel Lock to lock. So, that entire steering head, is adjusted On top of that we put our top triple clamp.
And we have a bolt. That we'll stick on here. We'll tighten this down to what is probably going to be about thirty pounds and just keep static pressure.
We don't want to do that until we get our fork tubes in the holes. I think now it is time to tighten everything up except the steering head.
This is a 8mm bolt, and I know that 8mm bolts, typically use a 14 foot pound torque so I've torqued that to 14 pounds
And I'll do the same, on the lower suspension. Ok again 14 foot pounds That is a 12mm bolt so I'm going to go up on the torque 35 pounds on that.
Next we've taken our fork. If you remembered we stripped these down with soda blasting. And we've painted them silver We've got new fork boots.
Our seal is in good shape so we did not change those They are easy to change if you need to.
What we'll do is we will now show these going up into the triple clamps. This is why we didn't do all that tightening awhile ago, so we can get these and get them right.
Everything is tight
To make sure that we have the wheel straight and true, Not over tight,
We spin it and we got good spin.