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Smoker's Custom Motard

415K views 2K replies 180 participants last post by  crazypj 
#1 ·
Been thinking A LOT about building a custom two-stroke motard. :D

I've got a nice 1987 RZ350, completely bone stock. I REALLY hate to strip it down to build a custom, but it's probably the best thing to do. It's already registered and plated here in California, so that will avoid a lot of future hassles.

So, now is the time for planning the build. Any ideas you guys may have would be much appreciated. I'll post up my ideas, and will get the work started when I feel comfortable with the design.

I want to use the existing RZ350 frame and engine, beyond that - it's wide open!! Soon, I'll post pics of the bike as it is now.

Here is a custom motard built with the same engine and frame:









 
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#307 ·
Sorry no progress to show, but I've been looking for an '85 California RZ350 to buy and use for the donor engine and electricals.

I have an '87 RZ350 that I can (and will) use if I don't find another bike. I'm backpedalling on using this bike, because it's probably worth about $5,000. (bone stock, low miles, good condition, zero damage).

Should have the Brembo front caliper in about a week.

Awesome news! Made contact with Brian Turfrey. :rock:

Brian is a living legend of two-stroke expansion chamber design and construction. I know he makes pipes for Eddie Lawson, Wayne Rainey, and lots of heavy hitters. And I'm not talking about back in the day - I mean now. Eddie and Wayne are still racing karts.

Hope it works out. I'll have to get the bike done and delivered to Brian and probably wait almost forever, but the prospect has me all juiced up because the pipes are one of the biggest hurdles to overcome on this project.
 
#309 ·
I don't have a clue, but I'm sure the number will make me cringe.

The off-the-shelf Lomas pipes I got for the streetfighter RZ350 were about a grand, so you can bet Turfrey's custom pipes will be at least double that price. Plus Brian always has projects waiting in line to be done, and he runs a race team. And if other race teams need stuff done fast, that gets priority.

Two-stroke pipe building is a very lucrative business to be in, if you know what you're doing.
 
#311 ·
Well, I'm just guessing 2 grand. If it's much more than that, there's a couple of other guys in Cali I may ask.

2-stroke pipe building requires a lot of knowledge and experience to make pipes that will maximize the potential horsepower in any engine. And it's somewhat of a crapshoot, unless you're willing to dyno and pay for other pipes to be built and tested. That's why it's best to have some one good do it right the first time.
 
#312 ·
hey smoker, i know of a guy in anaheim that specializes in expansion chambers. he does all the header/exhaust work for Chris over at MotoGP Werks.

he will also be doing my expansion chambers for the tr750.

i can get you his contact info if your interested.
 
#314 ·
k when i get home next week i will try and get you that info
 
#316 ·
I'm finding some California '85 RZ350s, but nothing cheap enough for a donor engine & frame.

These bikes sold for $2500 USD new. Now some are selling for double that (sometimes more)!

http://inlandempire.craigslist.org/mcy/1562661710.html

http://orangecounty.craigslist.org/mcy/1537769196.html

http://sfbay.craigslist.org/eby/mcy/1570615900.html

http://sfbay.craigslist.org/eby/mcy/1564512579.html

http://cgi.ebay.com/ebaymotors/Yama...c422eQQitemZ250569572910QQptZUSQ5fmotorcycles


Looking for something like this, except a California model (RZ350NC):

http://cgi.ebay.com/ebaymotors/Yama...846ceQQitemZ130361607886QQptZUSQ5fmotorcycles


Looks like this '85 Canadian will sell for $1,800:

http://cgi.ebay.com/ebaymotors/Yama...em7QQcategoryZ6718QQihZ012QQitemZ220543754993
 
#318 ·
K so i got the dudes info that does the expansion chambers.

Power Pro's Exhaust Systems in Placentia, Ca

and a few pics of what his work



 
#319 ·
theres also Highway Mans pipes. im sure you've herd of his expansion chambers.

and a kool, quick look at the process of expansion chamber building.
 
#324 ·
i check out that blog everyday.

i've even linked him to follow smokers builds. He will post up the pics on his site once its all complete.
 
#328 ·
how much work is involved with putting the RZ engine in there?
 
#331 ·
Been staring at the RZ engine and SXV frame for hours since yesterday just trying to figure out what it's going to take. The biggest problem is probably the pipes. I spent a lot of time trying to design some MX style (up) pipes, but didn't come up with anythng good. There's not going to be a lot of ground clearance with the down pipes, but I'll have to deal with it.

The other big issues are: The frame needs to be modified where it hits the intake manifolds, the intake manifolds need to be modified for clearance, and moving the carbs up and back to access the choke and idle screws through the frame. (This is looking at the stock carbs - still have to determine what carbs will be best). To get more ground clearance, I'd like to raise up the engine in the frame - which also looks better - but then the front sprocket is quite higher than the swingarm pivot.

Gonna take a break and then go to the hardware store to start getting parts to mock up the engine location. Also thinking about machined aluminum pieces to connect the tubing for the engine supports. More later.
 
#332 ·
There are holes drilled through the aluminum rear frame. The tubes of the steel front frame go through the holes, and bolts go in from the opposite side. There is also some kind if rubber-like adhesive in the hole for damping and strength. I'll see if I can find a pic.

I have concerns about powder-coating the frame, so I'll probably only paint, but I still need to weld engine mounts onto the steel and aluminum portions of the frame. That's probably not good.
 
#330 ·
First time I looked at this thread, all I can say is WOW!
 
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