r5 transmission issues (six speed swap)

[soonerbillz]

I'm very sorry to hear of your issues with this swap.
But do appreciate the thread as I'm doing the same swap on my R5. This post has really made me appreciate how important it is to be accurate when assembly of the 6 speed trans is attempted.

[mewherman]

Hey, thanks everyone for their help. I worked on the bike tonight, assembling the transmission component by component logically to determine the cause. I ended up finding that I had accidentally mixed up the tin shift drum collar (i'm not sure what else to call it) from the R5, the RD collar is very slightly larger and this was causing the shift drum to drag and not slide into the next gear. I've reassembled the engine, and it shifts through all the gears.

I haven't been able to run the engine yet, as I managed to snap the barb off one of the oil injection fittings on the cylinders, this is causing me major issues as I cannot find a replacement fitting online. The fitting is not the usual banjo style, it is one piece and pressed into the intake. I am only able to find the banjo fittings.

[rodneya]

The oil injection fittings are hard to find at the moment.
There is a guy  on the Yamaha RD Air Cooled facebook group  who is 3d printing them. Name is Steve Burgess

[mewherman]

The oil injection fittings are hard to find at the moment.
There is a guy  on the Yamaha RD Air Cooled facebook group  who is 3d printing them. Name is Steve Burgess

I can't even find a picture of these fittings, they are brass 90 degrees and are pressed into the location where the banjo fittings would normally go on the r5.

[1976RD400C]

I can't even find a picture of these fittings, they are brass 90 degrees and are pressed into the location where the banjo fittings would normally go on the r5.

This? Part 24   Looks like it is available.   https://www.yamahapartsmonster.com/oemparts/a/yam/50041640f8700209bc7846d0/oiil-pump

[m in sc]

Hey, thanks everyone for their help. I worked on the bike tonight, assembling the transmission component by component logically to determine the cause. I ended up finding that I had accidentally mixed up the tin shift drum collar (i'm not sure what else to call it) from the R5, the RD collar is very slightly larger and this was causing the shift drum to drag and not slide into the next gear. I've reassembled the engine, and it shifts through all the gears.

I haven't been able to run the engine yet, as I managed to snap the barb off one of the oil injection fittings on the cylinders, this is causing me major issues as I cannot find a replacement fitting online. The fitting is not the usual banjo style, it is one piece and pressed into the intake. I am only able to find the banjo fittings.

im pretty sure the cyl fitting is the same as the outlet one on the oil pump . ;)

side note.. makes sense on the drum. good catch.

[1976RD400C]

https://www.ebay.com/itm/203020611803

[mewherman]

Hey, thanks everyone for their help. I worked on the bike tonight, assembling the transmission component by component logically to determine the cause. I ended up finding that I had accidentally mixed up the tin shift drum collar (i'm not sure what else to call it) from the R5, the RD collar is very slightly larger and this was causing the shift drum to drag and not slide into the next gear. I've reassembled the engine, and it shifts through all the gears.

I haven't been able to run the engine yet, as I managed to snap the barb off one of the oil injection fittings on the cylinders, this is causing me major issues as I cannot find a replacement fitting online. The fitting is not the usual banjo style, it is one piece and pressed into the intake. I am only able to find the banjo fittings.

im pretty sure the cyl fitting is the same as the outlet one on the oil pump . ;)

side note.. makes sense on the drum. good catch.

I can't even find a picture of these fittings, they are brass 90 degrees and are pressed into the location where the banjo fittings would normally go on the r5.

This? Part 24   Looks like it is available.   https://www.yamahapartsmonster.com/oemparts/a/yam/50041640f8700209bc7846d0/oiil-pump

https://www.ebay.com/itm/203020611803

Managed to get one of the fittings NOS on eBay yesterday. Does anyone know why my old cylinders had the banjo style and these replacements had this type fitting? Is it a year thing?

Now that you mentioned that I actually have an old RD250 oil pump in my parts stash I should see if I can rob the fitting out of it, this fitting is the only thing stopping me from going for a ride.

[mewherman]

Hey, thanks everyone for their help. I worked on the bike tonight, assembling the transmission component by component logically to determine the cause. I ended up finding that I had accidentally mixed up the tin shift drum collar (i'm not sure what else to call it) from the R5, the RD collar is very slightly larger and this was causing the shift drum to drag and not slide into the next gear. I've reassembled the engine, and it shifts through all the gears.

I haven't been able to run the engine yet, as I managed to snap the barb off one of the oil injection fittings on the cylinders, this is causing me major issues as I cannot find a replacement fitting online. The fitting is not the usual banjo style, it is one piece and pressed into the intake. I am only able to find the banjo fittings.

im pretty sure the cyl fitting is the same as the outlet one on the oil pump . ;)

side note.. makes sense on the drum. good catch.

Just fyi, I removed a fitting from the oil pump and they are not the same.

[SoCal250]

If the fitting your are trying to source is a 90 degree press-in oil fitting with a barbed end, they are available. Don't know why you're having a hard time finding them. Although most dealers don't have them because it is a discontinued part.

According to my old parts book, the R5 & R5B used the press-in type nozzle fitting and the R5C used the banjo-bolt type.
Here are the two variants:
24        278-13552-02-00    NOZZLE (278-13552-01) 0 1
24-1     214-13162-01-00    BANJO, DLVRY PIPE

List of superseded parts for the Nozzle:
278-13552-00-00
278-13552-01-00
278-13552-02-00
3XV-13741-00-00

Quite a few on Ebay currently
https://www.ebay.com/sch/i.html?_from=R40&_trksid=p2380057.m570.l1313&_nkw=yamaha+278-13552&_sacat=0
https://www.ebay.com/sch/i.html?_from=R40&_trksid=p2047675.m570.l1313&_nkw=yamaha+3XV-13741&_sacat=0

Speed & Sport in PA has more than 50pcs in stock
Part #                      Description                    On Hand   Price
278-13552-02-00   3XV-13741-00-00 NOZZLE     20       $28.55
278-13552-01-00   278-13552-02-00 NOZZLE       4       $28.55
3XV-13741-00-00   NOZZLE                                31       $18.49

[mewherman]

If the fitting your are trying to source is a 90 degree press-in oil fitting with a barbed end, they are available. Don't know why you're having a hard time finding them. Although most dealers don't have them because it is a discontinued part.

According to my old parts book, the R5 & R5B used the press-in type nozzle fitting and the R5C used the banjo-bolt type.
Here are the two variants:
24        278-13552-02-00    NOZZLE (278-13552-01) 0 1
24-1     214-13162-01-00    BANJO, DLVRY PIPE

List of superseded parts for the Nozzle:
278-13552-00-00
278-13552-01-00
278-13552-02-00
3XV-13741-00-00

Quite a few on Ebay currently
https://www.ebay.com/sch/i.html?_from=R40&_trksid=p2380057.m570.l1313&_nkw=yamaha+278-13552&_sacat=0
https://www.ebay.com/sch/i.html?_from=R40&_trksid=p2047675.m570.l1313&_nkw=yamaha+3XV-13741&_sacat=0

Speed & Sport in PA has more than 50pcs in stock
Part #                      Description                    On Hand   Price
278-13552-02-00   3XV-13741-00-00 NOZZLE     20       $28.55
278-13552-01-00   278-13552-02-00 NOZZLE       4       $28.55
3XV-13741-00-00   NOZZLE                                31       $18.49

Oh I have ordered an NOS one on ebay, I just meant it wasn't available on Economy cycle or other similar sites, I was also using the wrong search terms because I didn't know it was a "nozzle". Thanks for all the information!