Home Restoration Restoration topics Yamaha CS2E, rebuilding the engine
Yamaha CS2E, rebuilding the engine

During our holidays In England i was very happy to see that my friend Graham Head had found time to repair the crankshaft of the Yamaha CS2E.

 

For many years Graham Head was more or less the "Founder" of the Classic Yamaha restoration in the U.K. but now he has slowed down a bit, which ultimately will happen to all of us.

 

Graham Head
Graham Head

Fortunately Graham still had a lot of usuable parts for the crank and here it is: (Mine was soo bad, Graham could not use a single part of it anymore!)

 

Yamaha CS2E, crankshaft
Yamaha CS2E, crankshaft

 


Together we also visited the Sammy Miller Motorcycle Museum, a few of the Yamaha racers there are Graham's bikes, like this superb TR2 350 cc racer.

 

Graham Head, Sammy Miller Museum
Graham Head, Sammy Miller Museum

 


Coming home and sorting all the parts for the engine I discovered that the r.h. crankcase was cracked. But fortunately Jesse, one of Yamaha Motor Europe's top mechanics, welded it for me. He learned aluminium welding from the Dutch frame wizzard Nico Bakker, so it is perfect!

 

Jesse-San, my super welder!
Jesse-San, my super welder!

 

Yamaha CS2E, r.h. crankcase
Yamaha CS2E, r.h. crankcase

 


The needle bearings are a little difficult to get in (mine were so bad that I had to change them, normally they are okay and do not need to be replaced. The easiest way is to press them in or like I did, use some nuts, bolts, washers and a small "tool", which is simply a round piece of aluminium with the bearing inner diameter (15 mm) and overall 0,5 mm shorter than the bearing and drilled for the 8mm bolt.

 

needle bearing puller
needle bearing puller

 


This way you can very easily fit the bearing without any damage with not to many tools. The socket you use on the inside of the crankcase.

 

Yamaha CS2E, installing needle bearing
Yamaha CS2E, installing needle bearing

 


To insert the ball-bearings I heat the cases up with a heat gun and press them in hydraulically. Use a little grease in the opening and on the bearing.

 

Yamaha CS2E, r.h. crankcase with bearings
Yamaha CS2E, r.h. crankcase with bearings

 


 

Yamaha CS2E, l.h. crankcase with bearings
Yamaha CS2E, l.h. crankcase with bearings

 


Before fitting the crankshaft we have to be absolutely sure about the clearances. Yamaha gives as crankshaft width over the outer webs 140 mm (+ 0,2 mm). This means that the inner clearance of both crankcase halves has to be maximum 70 mm including the required shims (0,05 mm and 0,03-0,05 mm).

 

Yamaha CS2E, measuring crankshaft
Yamaha CS2E, measuring crankshaft

At first we measure the crankshaft and it is within the Yamaha tolerances so most probably there will be no problems. (There is already 0,27 mm clearance, 140,0-139,73 mm)

 


Now I have to set the kalibermeter to 70,0 mm.

 

Yamaha CS2E, setting clearance
Yamaha CS2E, setting clearance

 


The crankcase halves can be measured. Use a steel ruler on top of the crankcases and put the driveside shim on the bearing (0,05 mm). The clearance is fortunately more than 70,0 mm, it is okay!

 

Yamaha CS2E, measuring clearance
Yamaha CS2E, measuring clearance

 


And as a last verification I have bolted the crankcase halves together and measure once more the distance between the ballbearings. I have about 0,35 mm extra, that must be okay for the whole procedure!

 

Yamaha CS2E, measuring inner clearance
Yamaha CS2E, measuring inner clearance

 

 
 

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