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Old Streetfighter Motorcycle Forum Post 01-01-2019, 10:08 AM   #1
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Default RZV 本当の夢

After 35 years of dreaming....this is the year the dream will be reality.
MotoGP bred V4 two stroke for the street.....the real Kenny Roberts/Eddie Lawson replica
I have the bike, now I need to build it to ride......




Proof of start date/point of bike progress to come....

A bit of history....will need translator though
https://bike-lineage.org/unpopular/rzv500r.html

.................................................. ...........................

2019 winter build off bike RZV500R
https://www.customfighters.com/forum...d.php?t=136718

__________MY TWO STROKE ADDICTION_____________
RGV VJ21 L____________GT 750 J__sold _____
RGV VJ22 FL_________ GT 750 long term cafe project___
RGV VJ22 N ______________RS 250 Cup Bike_________
RGV VJ23 T__________And one for the water...SX-R 800_
RZ 350_______________The cherry popper...KD 80_____
___________________RZV500R____________________
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Old Streetfighter Motorcycle Forum Post 01-01-2019, 06:47 PM   #2
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Default Re: RZV 本当の夢

This is a true NO BOLT UNTOUCHED rebuild, with a few possible changes as I go....



Yamaha's very first production aluminum frame....


2019 winter build off bike RZV500R
https://www.customfighters.com/forum...d.php?t=136718

__________MY TWO STROKE ADDICTION_____________
RGV VJ21 L____________GT 750 J__sold _____
RGV VJ22 FL_________ GT 750 long term cafe project___
RGV VJ22 N ______________RS 250 Cup Bike_________
RGV VJ23 T__________And one for the water...SX-R 800_
RZ 350_______________The cherry popper...KD 80_____
___________________RZV500R____________________
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Old Streetfighter Motorcycle Forum Post 01-01-2019, 07:37 PM   #3
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Default Re: RZV 本当の夢

I will repeat a little bit of how the project got to this point. And hopefully move only forward from here with progress.

July 1984 I bought a brand new Yamaha FJ1100.....the magazines said this was the baddest production bike made.
I was in love, but only a couple months later the magazines had a new cover model....that I wanted even more.
An aluminum frame JDM only GP replica, with no way to ever get one.



After untold half attempts at getting a RZ/RD 500, I decided if I'm going to do it.....quit fucking talking about it and do it.
I found one for sale in Japan....looked at a few very small pictures....made some connections....and committed my money



My middle man (woman actually) got the bike to her shop



Boxed it up and sent it to me



An untouched 6000 mile bike.
That let long term storage take it's toll on too many areas for me to neglect.
I put it back together to run it, and decide from there what I had to do
https://youtu.be/wUrWZCCEkY8

This was the last time the bike was ever seen in one piece....



That takes us to April 2018.....I tore the bike down, pulled the engine and found rust in the cylinders....which led me to a point that that shut the project down.
And me not giving a fuck about working on anything anymore.
I bought a new bike to ride, and did just that until winter came back to put me in my place.

Back in the garage.



.................................................. .................................................. ............

2019 winter build off bike RZV500R
https://www.customfighters.com/forum...d.php?t=136718

__________MY TWO STROKE ADDICTION_____________
RGV VJ21 L____________GT 750 J__sold _____
RGV VJ22 FL_________ GT 750 long term cafe project___
RGV VJ22 N ______________RS 250 Cup Bike_________
RGV VJ23 T__________And one for the water...SX-R 800_
RZ 350_______________The cherry popper...KD 80_____
___________________RZV500R____________________
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Old Streetfighter Motorcycle Forum Post 01-02-2019, 07:19 PM   #4
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Default Re: RZV 本当の夢

Cranks are out and ready to ship out.



Cases are cleaned up, inside and out as well as flushing out the transmission.
Ready for cranks when they get back from rebuild.
Clutch pulled and checked/cleaned up.



As much as I had wanted to keep this completely original....
I knew I had to put different/lighter more powerful pipes on it.
And I really did not want to run skinny tires on the oldskool 16/18 combo....
Not sure what route I will take with wheels yet, but the FZR1000 front and rear I have right now, are an easy swap.
But....I might also swap forks, and if I do that I'll have to swap calipers and master too....and then it just goes on to a project that will never be done.

So, I really need to focus on simplicity/functionality/and ease to take it back to completely original.
Because in another 15 years when I put this on permanent display in the basement, functionality won't matter.



Wheels will be....any color other than white....probably very dark grey metallic

.................................................. .................................................. ......................

2019 winter build off bike RZV500R
https://www.customfighters.com/forum...d.php?t=136718

__________MY TWO STROKE ADDICTION_____________
RGV VJ21 L____________GT 750 J__sold _____
RGV VJ22 FL_________ GT 750 long term cafe project___
RGV VJ22 N ______________RS 250 Cup Bike_________
RGV VJ23 T__________And one for the water...SX-R 800_
RZ 350_______________The cherry popper...KD 80_____
___________________RZV500R____________________
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Old Streetfighter Motorcycle Forum Post 01-03-2019, 04:20 PM   #5
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Default Re: RZV 本当の夢

Dug the carbs out after I cleaned the cranks up to double check bearings (and deciding to just get ALL new bearings and not think about it anymore)
Looks like it will be in the upper 40's tomorrow, so I will soda blast the outside of the carbs first.
Then put them in the sonic cleaner for about an hour for all the internal areas.



Inquired about the possibility of boring out the stock carbs from 26mm to 28mm....I know...small either way.
But simple options are few, and cheap options non existent.



Might do a bit of porting to try and fit bigger reed cages in as well.
The stock reed cages are incredibly small, severely limiting the potential of the bulletproof bottom end.
Here is the difference between the RZV500 reed and the RGV250 VJ21 reed
This is why the VJ21 was the very first production bike to break the 200HP per liter limit.




.................................................. .................................................. ..

2019 winter build off bike RZV500R
https://www.customfighters.com/forum...d.php?t=136718

__________MY TWO STROKE ADDICTION_____________
RGV VJ21 L____________GT 750 J__sold _____
RGV VJ22 FL_________ GT 750 long term cafe project___
RGV VJ22 N ______________RS 250 Cup Bike_________
RGV VJ23 T__________And one for the water...SX-R 800_
RZ 350_______________The cherry popper...KD 80_____
___________________RZV500R____________________
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Old Streetfighter Motorcycle Forum Post 01-05-2019, 10:54 PM   #6
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Default Re: RZV 本当の夢

More wheel possibilities...
02YZF600R 17x5



It is posing some fitment issues though, more questions than answers so far.
Next is possibly a 89 up FZR 1000 17x5.5.....?



.................................................. .................................................. .............

2019 winter build off bike RZV500R
https://www.customfighters.com/forum...d.php?t=136718

__________MY TWO STROKE ADDICTION_____________
RGV VJ21 L____________GT 750 J__sold _____
RGV VJ22 FL_________ GT 750 long term cafe project___
RGV VJ22 N ______________RS 250 Cup Bike_________
RGV VJ23 T__________And one for the water...SX-R 800_
RZ 350_______________The cherry popper...KD 80_____
___________________RZV500R____________________
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Old Streetfighter Motorcycle Forum Post 01-06-2019, 10:55 AM   #7
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Default Re: RZV 本当の夢

Carbs are completely stripped and now spotless, inside and out.
Sadly since this was a restricted home market bike, all the jets and needles will have to be changed....
....sad because it will be all trail and error/seat of the pants tuning work.
Which is dependant on what pipes I use as well as reed valves and ignition timing curve.
And that takes a lot of time, before it will be good enough to then go to the dyno.

One step at a time I guess.


2019 winter build off bike RZV500R
https://www.customfighters.com/forum...d.php?t=136718

__________MY TWO STROKE ADDICTION_____________
RGV VJ21 L____________GT 750 J__sold _____
RGV VJ22 FL_________ GT 750 long term cafe project___
RGV VJ22 N ______________RS 250 Cup Bike_________
RGV VJ23 T__________And one for the water...SX-R 800_
RZ 350_______________The cherry popper...KD 80_____
___________________RZV500R____________________
busa1300 is offline   Reply With Quote on our streetfighter motorcycle forum
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Old Streetfighter Motorcycle Forum Post 01-15-2019, 06:31 PM   #8
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Default Re: RZV 本当の夢

More done.
Soda blasted my heads and cylinders when I blasted my carbs.
Finally got around to getting the parts masked of correctly so I could repaint them.
Used acid etch primer then single stage polyurethane semigloss black at work.
Pulled tape off when I got home, then put them in the oven for a couple hours at 200 degrees.





Pistons and main bearings showed up Monday, and my rod bearings should be here tomorrow.
Then I can get my cylinders sent off for rebore, and cranks 100% rebuilt throughout.


.................................................. ................................................

2019 winter build off bike RZV500R
https://www.customfighters.com/forum...d.php?t=136718

__________MY TWO STROKE ADDICTION_____________
RGV VJ21 L____________GT 750 J__sold _____
RGV VJ22 FL_________ GT 750 long term cafe project___
RGV VJ22 N ______________RS 250 Cup Bike_________
RGV VJ23 T__________And one for the water...SX-R 800_
RZ 350_______________The cherry popper...KD 80_____
___________________RZV500R____________________
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Old Streetfighter Motorcycle Forum Post 02-20-2019, 09:49 PM   #9
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Default Re: RZV 本当の夢

Bought the correct Koyo/Yamaha bearings for the cranks, and sent them out for a rebuild.
Two weeks later....and $$$....
And I just got them back today, now I can really start making some progress....






Cylinders were sent out at the same time for a rebore to get rid of the fucking rust.
Came back looking new, Put my cleaned up powervalves in with all new seals.
Ready to get some pistons put in them now.





2019 winter build off bike RZV500R
https://www.customfighters.com/forum...d.php?t=136718

__________MY TWO STROKE ADDICTION_____________
RGV VJ21 L____________GT 750 J__sold _____
RGV VJ22 FL_________ GT 750 long term cafe project___
RGV VJ22 N ______________RS 250 Cup Bike_________
RGV VJ23 T__________And one for the water...SX-R 800_
RZ 350_______________The cherry popper...KD 80_____
___________________RZV500R____________________
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Old Streetfighter Motorcycle Forum Post 02-20-2019, 10:03 PM   #10
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Default Re: RZV 本当の夢

Other areas of progress.....
Rebuilding FZR forks.



320 rotors are cleaned up and ready to bolt on.



Put in new steering head bearings.



And used paint remover and the soda blaster to get wheel ready for paint.....(maybe tomorrow)


2019 winter build off bike RZV500R
https://www.customfighters.com/forum...d.php?t=136718

__________MY TWO STROKE ADDICTION_____________
RGV VJ21 L____________GT 750 J__sold _____
RGV VJ22 FL_________ GT 750 long term cafe project___
RGV VJ22 N ______________RS 250 Cup Bike_________
RGV VJ23 T__________And one for the water...SX-R 800_
RZ 350_______________The cherry popper...KD 80_____
___________________RZV500R____________________
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