Home Restoration Restoration topics Yamaha YDS5 (DS2-DS3-DS6) assembly
Yamaha YDS5 (DS2-DS3-DS6) assembly

Now we can fit the engine in the frame and start completing the bike.

The frame/cycle is ready to accept the engine:

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Lift the engine by the kickstarter and the starter generator and slide it in carefully from the left hand side! Move the engine above the brackets and when in place lower the motor carefully. It should fit in one go! Put the bolts in from the r.h. side.

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Now you can attach the chain, chainguard, batterybox and the other parts you can view on this picture.

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On the engine you have to be careful with the order of attaching the parts, otherwise you run into trouble later. Start by attaching the tachometer cable, next the autolubepump cable (after you have assembled the throttlewire assembly of course), now you can fit the carburetors:

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Fit the airfilter box loosely, that is the only way to attach the carburetor rubbers without damage. After fitting the 4 clamps you can attach the airfilterbox.

Just received the painted parts from one of the specialists in Holland, click on the picture to see the superb "Candy Red" colour.

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The DS5 is ready now to take the coloured parts. I had a pair of painted and chromed rear shockabsorbers already from many years ago......!

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I always grease all the painted parts when I fit them, this helps a lot. First fit the front fork shrouds and the headlampstays.

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It looks now already a little like a motorcycle!

 


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Next fit the headlamp complete with speedometer and speedometer/tachometer cables, (not the ignition lock at this stage)

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Now carefully connect all the wires from the wiring harness with those of the handlebarunits left and right and finally connect the ignition lock wires to it. Now you can smoothly move all the electric wires in the headlampshell without causing a shortage. You do not have to ground the headlamp as this is done by the rev-counter cable (metal from the speedometer to the engine). Take care in fitting the headlamplens, when you position it carefully, it clicks straight over the "bumps" in the headlampshell.