500 Two-Stroke Tech

Hi

Here is my project.
No big words - i`ve got a RD500 for free
The only thing i had to do is to rebuild a Benelli 250 2C that was in relative good condition.
I paid 700€ for parts and this was the result:



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And this is what i got:





It has 40000km on the clock with the first pistons etc. and it is (besides the colour) 98% original. Just a hand full of screws are not original.

The first work was to clean the carbs:




And then to ride it
http://www.youtube.com/watch?v=KS_E1l6I ... e=youtu.be

This is the bike now:



The frame has a crack because someone of the pevious owners has forgotten the lower rear engine mounting bolt.
So i have to weld it and then it gets new paint.

At the end, the bike should look like new


I`m new in this group
My name is Michael, 23 years old and i am from austria!

here are some pictures of my other bikes

The 500 looks really clean for the money!! I'm surprised he didn't charge you extra for the custom paint job!!

Hi Michael,
welcome to the board! I am from Vienna, just 2 hours away from you.
Nice location you live at, directly at RED BULL race track!

I am not sure if we ever met at various events I visited in Zeltweg/Spielberg, including DUCATI Speed weeks, Hollaus Gedenkrennen etc.
I have 3x RD500, 1x RD350YPVS 31k, 1x TZR250RS 3XV, 1x TDR250 3CK, 1x NSR400, 1x GT750 (Wasserbüffel), 3x DUCATI, etc

I´ll send you a PM with contact details,

best regards

Wolfgang

Hi Michael,
welcome to the board! I am from Vienna, just 2 hours away from you.
Nice location you live at, directly at RED BULL race track!

I am not sure if we ever met at various events I visited in Zeltweg/Spielberg, including DUCATI Speed weeks, Hollaus Gedenkrennen etc.
I have 3x RD500, 1x RD350YPVS 31k, 1x TZR250RS 3XV, 1x TDR250 3CK, 1x NSR400, 1x GT750 (Wasserbüffel), 3x DUCATI, etc

I´ll send you a PM with contact details,

best regards

Wolfgang

Jeff B wrote:The 500 looks really clean for the money!!

On the pictures it looks like it is in good condition but there are much things to do.

1) The crack in the frame
2) Steering head bearing
3) All bearings of the swing arm/shock absorber
4) All plastic parts are repaired (except the 2 rear parts) and in not so good condition.

It had a crash on the left side, most parts are new/unscratched but when you look exactly, all little holders etc. are bent, the left exhaust doesnt`t fit correct and so on.
But i think there was no one working around on this bike, the most screws look like they were not opened all the time.

All in all it is a really good bike for this money! It has been ridden all the time.
Normal price here is 6-10000€ for one in (really) good condition and i think ~3-4000€ for one in this condition.
But it`s hard to find one with a good engine...

Some little news:

The bike is completely disassembled.
The next step is to sandblast, weld and paint the frame.
Then i`ll replace all bearings (steering head, shock absorber, swing arm) and rebuild the fork.

Besides i have another project.
I have digitized the entire parts catalog of the 1GE and will summarize all the data of the parts in a database (with a picture).

As an example:


At the time it`s in microsoft excel.
When it is finished it should be a database with all informations like thread diameter/length/head dimension of all screws, the data of standardized bearings like the swing arm bearing (IKO TA2428Z), color codes, material, alternative parts (aftermarket) for parts that are not longer available and so on.

Maybe i`ll put this database online, so that all RD500 enthusiasts have access to it.

Wow, That sounds fantastic. Looking forward to seeing it.

Speed Freak wrote: Maybe i`ll put this database online, so that all RD500 enthusiasts have access to it.

Excellent. Thanks for the work you're putting into it.
It would be great for anyone with an RD/RZ 500.

Part number with photo would be great

You got an excellent deal on the bike.

I think i need the help of the board for the parts catalog
The goal is to get a photo in original/new condition from each part.


Back to the bike.






I`ve ordered all bearings for the swing arm and now i have to wait till the yamaha dealer opens (winter holidays...), so that i can order the rest of the parts i need.
The 2 plastic bushings in the smaler relay arm get replaced by needle bearings. For this new needle bearings i have to make new hardened collars.
I hope there is no clearance in all parts after the repair.

While i`m waiting for parts i have cleaned the engine and disassembled the cylinders.





They are in good condition, just the lower right one has a scratch on the exhaust side.
I hope it`s not too deep, so i can use the 1st oversize piston.

You got an excellent deal on the bike

From time to time i don`t think so
All things that are really expensive and rare are damaged...

I thought that the YPVS valves are in good condition, but i have just checked the rear ones.
The front valves are worn and they are stuck at closed position.
The only positive thing in this case - there is much more power when they are working
I missed the real 2-stroke punch.

The plan is to make new bearing caps with higher quality brass bushings in it and when it`s possible with the machines i, or better a friend of mine has acces to, to make new YPVS valves.
I`m dreaming about aluminium valves with little steel bearing rings on it...

Yesterday i have bought a second RD500 for 650€.
Not cheap, but when i`m selling it in parts i`ll get the money back.

It`s in really bad condition, but there are some parts i need for my restoration like lower fork tubes in good condition, original wire harness, battery box with all rubber parts, not bent sidestand etc.

The engine is also in bad condition. 2 pistons are damaged. I got just 2 cylinders and one of them is damaged. Both cylinders have helicoil inserts in the exhaust bolt threads...
The crankshafts are unusable because the conrod little end bearings are damaged.
I hope the clutch, generator, gears etc. are in good condition.
And i have got 2 good YPVS valves















And please no questions about the paint job... I dont know what they though at the beginning of the 90s

Hi,

Your database sound fanastic and just like what I need. I am restoring a 500 to original and have been trying to establish what the factory finish is to all the parts as well. Have you made much progress with the database or confirmed finish on some of the parts?

I would be really bgrateful for any info you can give on this.

Regards
B

Sorry, i have to disappoint you.

There is no time for my project and my RD500 is on the other side of the world...
I`m in Japan for a half year or longer and here it is normal to work 12h/day or more.

At the time i have just pictures and specs of the whole original gasket set and the most of the rear arm/suspension parts.

When i find some time i`ll put them together into the database or build up a website.

Slow but there is progress now.

I have tried out my new sand blasting cabin:







The silver stuff on one bracket is paint, the other one is ready for a new zinc layer.


In 2 weeks i have holidays - time to do some big stuff.
- Frame welding
- Searching for a company that can replate all my bolts and brackets
- Searching for a good powder coating company
- Maybe sandblasting the frame and powder coat/paint it new (depends if i get the correct color with powder coating).

Some new very small progress...

One of the first parts that is ready to put it back into the bike (except all the new parts)


Coolant temperature sensor.

Rest of the progress is not possible to show... Just disassembled nearly everything and stored it into plastic bags/boxes with part number.
Frame is welded and would be ready for sand blasting and paint, but i can`t decide - powder coating or paint?

Anyway, next step is to measure every bolt and take a picture, then i throw them color by color together in a box to replate everything.
A lot of work for my holidays