I always use the system of putting all parts in small boxes following the Yamaha parts lists. That way you can check all components easily and see what is missing and need replacement......

Yamaha DS5 parts

DS5 small bits

DS5 wheel building

I always start by building-up the wheels. Then you have something big already. After polishing the hubs (you look absolutely like a monkey!) you can either look for new wheel rims or recondition the old ones. Many times carefull polishing with steelwool gives a useable part if money is tight. Same goes for the spokes.

Before "lacing"the wheel fit the bearings. Always heat the hub up on an electric stoveplate and insert the bearings always with a mandrel.

DS5 wheel trueing

Trueing the wheels is not really difficult, tighten the spooks gradually on 4 opposite points in groups of 4 spokes each. This way you get already a tentative correct wheel. After that you tighten the remaining spokes.

When the wheels are complete you can turn your attention to the rearsprockethub assembly and the front brake plate. Please note that for these old Yamaha's (YDS3-YDS5-DS6, etc.) rear brake shoes are still available! Partnumber 5R3-W253E-00-00. The Front ones are unfortunately not available anymore.

DS5 sprocket carrier

DS5 front hub

Now you can have a look at the frame. Always fit firstly the steering head bearing cups, the mainstand and the side stand. I always make new oversize bolts for the main stand as the old ones are always very worn. Steeringhead bearings still available, Partnumbers 156-23411-00-00 (race, ball 1) and 156-23412-00 (race, ball 2)

DS5 frame

Next you must pre-assemble the steering under bracket. Here you see all the parts, also the old-type steering damper. When you are sure everything is okay you can fit it to the frame. Next slide-in the assembled forktubes and attache the rear-swinging arm.

DS5 front fork yoke

Now it is time to turn the whole thing upside-down and fit the wheels temporarily. Try to make and use a headstay as I have here. It is a simple tubular thing and the rod fits in the hole on the underside of the steering under bracket.

DS5 frame-wheel assembly

Next we start with the engine.