RZ500 and RZV500 restore and rebuild

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tacky1
Posts: 1248
Joined: Mon Sep 14, 2015 12:30 pm
Location: Bay Area. CA.

RZ500 and RZV500 restore and rebuild

#1 Post by tacky1 » Thu Dec 24, 2015 3:03 am

I bought two bikes, 2 RZ500's, One in a box, completely dismembered, the other one a roller with brand new Black/Red complete bodywork kit, Toomeys etc, It runs, badly.
Soooooooo, I have just finished rebuilding the motor out of the box, I oped up all the ports and to a tweaked TSI spec, fitted Vforce3 reeds, 28mm carbs, Heads were already machined down and squish and domes are all reworked.

This is what I bought... :)

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1985 RZv500
1984 RZ500 Hybrid
1986 RG500 Walter Wolf
1986 RG500 Skoal Bandit
1984 RZ350
1984 RZ350 Hybrid
1981 RD350LC
1981 RD350LC Hybrid
2009 CR500AF Supermoto 250X
2007 CR500AF 250X
1988 YSR50 (2)
1989 VFR750R RC30
1984 GPZ750 Turbo

User avatar
tacky1
Posts: 1248
Joined: Mon Sep 14, 2015 12:30 pm
Location: Bay Area. CA.

Re: RZ500 and RZV500 restore and rebuild

#2 Post by tacky1 » Thu Dec 24, 2015 3:08 am

The seller also had this frame, So I ended up buying it from him..

Image
1985 RZv500
1984 RZ500 Hybrid
1986 RG500 Walter Wolf
1986 RG500 Skoal Bandit
1984 RZ350
1984 RZ350 Hybrid
1981 RD350LC
1981 RD350LC Hybrid
2009 CR500AF Supermoto 250X
2007 CR500AF 250X
1988 YSR50 (2)
1989 VFR750R RC30
1984 GPZ750 Turbo

User avatar
tacky1
Posts: 1248
Joined: Mon Sep 14, 2015 12:30 pm
Location: Bay Area. CA.

Re: RZ500 and RZV500 restore and rebuild

#3 Post by tacky1 » Thu Dec 24, 2015 3:11 am

It came with a crap load of new seals, gaskets bolts washer etc. Plus I spent over a Grand at Megazip and bought everything else that was need to finish both bikes with all new nuts, bolts etc.

Image
1985 RZv500
1984 RZ500 Hybrid
1986 RG500 Walter Wolf
1986 RG500 Skoal Bandit
1984 RZ350
1984 RZ350 Hybrid
1981 RD350LC
1981 RD350LC Hybrid
2009 CR500AF Supermoto 250X
2007 CR500AF 250X
1988 YSR50 (2)
1989 VFR750R RC30
1984 GPZ750 Turbo

User avatar
tacky1
Posts: 1248
Joined: Mon Sep 14, 2015 12:30 pm
Location: Bay Area. CA.

Re: RZ500 and RZV500 restore and rebuild

#4 Post by tacky1 » Thu Dec 24, 2015 3:18 am

Engine number one all cleaned up and washed ready for paint

Image
1985 RZv500
1984 RZ500 Hybrid
1986 RG500 Walter Wolf
1986 RG500 Skoal Bandit
1984 RZ350
1984 RZ350 Hybrid
1981 RD350LC
1981 RD350LC Hybrid
2009 CR500AF Supermoto 250X
2007 CR500AF 250X
1988 YSR50 (2)
1989 VFR750R RC30
1984 GPZ750 Turbo

User avatar
tacky1
Posts: 1248
Joined: Mon Sep 14, 2015 12:30 pm
Location: Bay Area. CA.

Re: RZ500 and RZV500 restore and rebuild

#5 Post by tacky1 » Thu Dec 24, 2015 3:19 am

And painted.. :)
Cases and heads are gloss, The main cases and barrels are semi gloss, Primed, paint and clear

Image
1985 RZv500
1984 RZ500 Hybrid
1986 RG500 Walter Wolf
1986 RG500 Skoal Bandit
1984 RZ350
1984 RZ350 Hybrid
1981 RD350LC
1981 RD350LC Hybrid
2009 CR500AF Supermoto 250X
2007 CR500AF 250X
1988 YSR50 (2)
1989 VFR750R RC30
1984 GPZ750 Turbo

User avatar
tacky1
Posts: 1248
Joined: Mon Sep 14, 2015 12:30 pm
Location: Bay Area. CA.

Re: RZ500 and RZV500 restore and rebuild

#6 Post by tacky1 » Thu Dec 24, 2015 3:23 am

Cranks were rebuilt and welded by Crank Works in AZ, I have got most of my cranks rebuilt with them, good guys.
Rebored cylinders by engine dynamics in petaluma

Image
1985 RZv500
1984 RZ500 Hybrid
1986 RG500 Walter Wolf
1986 RG500 Skoal Bandit
1984 RZ350
1984 RZ350 Hybrid
1981 RD350LC
1981 RD350LC Hybrid
2009 CR500AF Supermoto 250X
2007 CR500AF 250X
1988 YSR50 (2)
1989 VFR750R RC30
1984 GPZ750 Turbo

User avatar
tacky1
Posts: 1248
Joined: Mon Sep 14, 2015 12:30 pm
Location: Bay Area. CA.

Re: RZ500 and RZV500 restore and rebuild

#7 Post by tacky1 » Thu Dec 24, 2015 3:23 am

All ready to build

Image
1985 RZv500
1984 RZ500 Hybrid
1986 RG500 Walter Wolf
1986 RG500 Skoal Bandit
1984 RZ350
1984 RZ350 Hybrid
1981 RD350LC
1981 RD350LC Hybrid
2009 CR500AF Supermoto 250X
2007 CR500AF 250X
1988 YSR50 (2)
1989 VFR750R RC30
1984 GPZ750 Turbo

User avatar
tacky1
Posts: 1248
Joined: Mon Sep 14, 2015 12:30 pm
Location: Bay Area. CA.

Re: RZ500 and RZV500 restore and rebuild

#8 Post by tacky1 » Thu Dec 24, 2015 3:25 am

Cases together

Image
1985 RZv500
1984 RZ500 Hybrid
1986 RG500 Walter Wolf
1986 RG500 Skoal Bandit
1984 RZ350
1984 RZ350 Hybrid
1981 RD350LC
1981 RD350LC Hybrid
2009 CR500AF Supermoto 250X
2007 CR500AF 250X
1988 YSR50 (2)
1989 VFR750R RC30
1984 GPZ750 Turbo

User avatar
tacky1
Posts: 1248
Joined: Mon Sep 14, 2015 12:30 pm
Location: Bay Area. CA.

Re: RZ500 and RZV500 restore and rebuild

#9 Post by tacky1 » Thu Dec 24, 2015 3:27 am

Stock and TSI timing, I decided to run the balance shaft off the rear crank and left out the anti lash gears.

Stock timing
Image


TSI timing

Image
1985 RZv500
1984 RZ500 Hybrid
1986 RG500 Walter Wolf
1986 RG500 Skoal Bandit
1984 RZ350
1984 RZ350 Hybrid
1981 RD350LC
1981 RD350LC Hybrid
2009 CR500AF Supermoto 250X
2007 CR500AF 250X
1988 YSR50 (2)
1989 VFR750R RC30
1984 GPZ750 Turbo

User avatar
tacky1
Posts: 1248
Joined: Mon Sep 14, 2015 12:30 pm
Location: Bay Area. CA.

Re: RZ500 and RZV500 restore and rebuild

#10 Post by tacky1 » Thu Dec 24, 2015 3:32 am

And done, That was the easy part, Now the part where I have to strip and redo the frames, all bearings, seals, tires etc, The RZV frame is going to be 100% stock rebuild, The RZ will be on 2008 R6 suspension, Ohlins shock, Front forks have race tech springs and 15w oil, Toomeys and this motor, It will have the Red/Black bodywork.



Image

Image

Image

Image
1985 RZv500
1984 RZ500 Hybrid
1986 RG500 Walter Wolf
1986 RG500 Skoal Bandit
1984 RZ350
1984 RZ350 Hybrid
1981 RD350LC
1981 RD350LC Hybrid
2009 CR500AF Supermoto 250X
2007 CR500AF 250X
1988 YSR50 (2)
1989 VFR750R RC30
1984 GPZ750 Turbo

User avatar
tacky1
Posts: 1248
Joined: Mon Sep 14, 2015 12:30 pm
Location: Bay Area. CA.

Re: RZ500 and RZV500 restore and rebuild

#11 Post by tacky1 » Thu Dec 24, 2015 3:34 am

I also have a 4 degree key in there..

Image

Stock exhaust VS modded port

Image
1985 RZv500
1984 RZ500 Hybrid
1986 RG500 Walter Wolf
1986 RG500 Skoal Bandit
1984 RZ350
1984 RZ350 Hybrid
1981 RD350LC
1981 RD350LC Hybrid
2009 CR500AF Supermoto 250X
2007 CR500AF 250X
1988 YSR50 (2)
1989 VFR750R RC30
1984 GPZ750 Turbo

User avatar
tacky1
Posts: 1248
Joined: Mon Sep 14, 2015 12:30 pm
Location: Bay Area. CA.

Re: RZ500 and RZV500 restore and rebuild

#12 Post by tacky1 » Thu Dec 24, 2015 3:35 am

That's it, That's as far as I have got so far.. :)
1985 RZv500
1984 RZ500 Hybrid
1986 RG500 Walter Wolf
1986 RG500 Skoal Bandit
1984 RZ350
1984 RZ350 Hybrid
1981 RD350LC
1981 RD350LC Hybrid
2009 CR500AF Supermoto 250X
2007 CR500AF 250X
1988 YSR50 (2)
1989 VFR750R RC30
1984 GPZ750 Turbo

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Smoker
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Re: RZ500 and RZV500 restore and rebuild

#13 Post by Smoker » Thu Dec 24, 2015 6:14 am

Very nice work.

Have you had previous experience with RZ500s?

Vin
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Re: RZ500 and RZV500 restore and rebuild

#14 Post by Vin » Thu Dec 24, 2015 7:34 am

Great work and update tacky1 :cool:

rd84
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Re: RZ500 and RZV500 restore and rebuild

#15 Post by rd84 » Thu Dec 24, 2015 8:52 am

Nice work and thanks for showing the progress on your project - always useful and inspiring to see.

Cheers
Paul

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