RZV500R....An attempt at turning back the clock

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busa1300
Posts: 282
Joined: Sat Feb 01, 2014 11:45 am
Location: N Indiana

RZV500R....An attempt at turning back the clock

#1 Post by busa1300 » Mon Mar 26, 2018 9:34 pm

9884KM....
Should look almost new.....but the 34 years of riding/storage in Japanese environments has taken it's toll.
I am going to attempt to turn back time to some degree, yet leave enough patina to consider it unrestored when done....
At least that is what I am hoping....
First thing was getting it up on the operating table to get the R1 calipers and radial master cylinder off.
I had a set of calipers and master from my 84 FJ1100 that I have kept in various boxes since 1987 (bike was totaled)
All a perfect fit.....I knew I kept them parts around for a reason :mrgreen:

Anyway, bought some stainless lines and played around a bit to test fit them, and have new HH pads for the rear to match up with the ones on the front calipers. Not as good as the R1 set up, but the originals just look like they should. Have a box of parts ordered to get the front and rear end cleaned up a bit (bearing/seals...). And have a set of correct mirrors on the way along with another YPVS box from Japan. TSA pipes ordered from the UK....and trying to decide on what tires to get for these damn rims now...???

Here's where it starts... :smt007
IMG_1400 - Copy.JPG
IMG_1400 - Copy.JPG (250.18 KiB) Viewed 7690 times
Lights off for now....until some parts start to show up in a few more days.
IMG_1419 - Copy.JPG
IMG_1419 - Copy.JPG (232.69 KiB) Viewed 7690 times
This is picking up, from where this led from
http://www.rzrd500.com/500phpBB3/viewto ... 13&t=15238" onclick="window.open(this.href);return false;
78 GS1000E
80 KD80
82 Katana
84 RZ350
84 RZV500R
86 GSXR1100
86 1100 sportster
88 FZR1000
89 RGV250 VJ21 SP
90 RGV250 VJ22 SP
91 TZR250 3XV2 SP
96 RGV250 VJ23 T SP
99 RS250
02 Hayabusa
16 KTM 390 Duke
17 KTM 1290 Superduke GT
21 Aprilia RSV4 1100

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busa1300
Posts: 282
Joined: Sat Feb 01, 2014 11:45 am
Location: N Indiana

Re: RZV500R....An attempt at turning back the clock

#2 Post by busa1300 » Tue Mar 27, 2018 8:55 pm

I lied.....

Couldn't wait till parts showed, and had to dig in today.
IMG_1471 (2).JPG
IMG_1471 (2).JPG (248.58 KiB) Viewed 7612 times

The powervalves were not working, and I was under the assumption that is was the control box.
The pipes had to come off no matter what, and it's easier to get at the servo to test with them off.
Connected servo to a battery, and valves and actuation all seems to work great. Checked wiring to the control box and that was good too.
So the control box I have coming should take care of the issue....possibly go to a Zeel ignition if I need more HP than just the pipes can give.
IMG_1434.JPG
IMG_1434.JPG (233.32 KiB) Viewed 7612 times
Valve opens....and closes....damn that is a small port. :smt017
IMG_1493.JPG
IMG_1493.JPG (240.47 KiB) Viewed 7612 times
78 GS1000E
80 KD80
82 Katana
84 RZ350
84 RZV500R
86 GSXR1100
86 1100 sportster
88 FZR1000
89 RGV250 VJ21 SP
90 RGV250 VJ22 SP
91 TZR250 3XV2 SP
96 RGV250 VJ23 T SP
99 RS250
02 Hayabusa
16 KTM 390 Duke
17 KTM 1290 Superduke GT
21 Aprilia RSV4 1100

BigGuy
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Location: Maidstone, Ontario

Re: RZV500R....An attempt at turning back the clock

#3 Post by BigGuy » Wed Mar 28, 2018 7:59 am

Exciting stuff, nothing like going over a new toy!

Enjoy sir
Shake "N" Bake!

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ns86
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Joined: Sat Oct 30, 2010 9:46 pm
Location: ontario canada

Re: RZV500R....An attempt at turning back the clock

#4 Post by ns86 » Wed Mar 28, 2018 11:34 am

The fun begins! Are you selling those RZ mirrors? Hmmmm
1985 RZ500
1986 RG500
1986 RG500 C
1992 RGV500 WW ATR
1992 RGV500 LS
1985 NS500 Spencer p
1989 TZR500 Biaggi p
1984 RZV500 Rainey p
1994 NSR250sp R
1983 NS250 p
1987 RG250 WW p
1983 RG250 p
1988 YSR50 p

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busa1300
Posts: 282
Joined: Sat Feb 01, 2014 11:45 am
Location: N Indiana

Re: RZV500R....An attempt at turning back the clock

#5 Post by busa1300 » Thu Mar 29, 2018 4:14 pm

Was planning on just a cleanup....but I might get carried away like I did on my RGV VJ23....
Speaking of mirrors...some parts showed up...
...was going to show a few pics....but site says I have reached my board attachment quota...
78 GS1000E
80 KD80
82 Katana
84 RZ350
84 RZV500R
86 GSXR1100
86 1100 sportster
88 FZR1000
89 RGV250 VJ21 SP
90 RGV250 VJ22 SP
91 TZR250 3XV2 SP
96 RGV250 VJ23 T SP
99 RS250
02 Hayabusa
16 KTM 390 Duke
17 KTM 1290 Superduke GT
21 Aprilia RSV4 1100

begbie
Posts: 289
Joined: Fri Sep 02, 2011 7:02 pm
Location: UK

Re: RZV500R....An attempt at turning back the clock

#6 Post by begbie » Thu Mar 29, 2018 4:36 pm

Check the 10 amp fuses in the cockpit, The ypvs shares a circuit with the temp regulator sender If this shorts and blows the fuse your ypvs will cease to function. Happened to mine.
Last edited by begbie on Thu Mar 29, 2018 6:05 pm, edited 1 time in total.

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nzminis
Posts: 479
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Location: New zealand

Re: RZV500R....An attempt at turning back the clock

#7 Post by nzminis » Thu Mar 29, 2018 5:23 pm

ive been having problems with my ypvs , been a real ass to figure out
few control boxes and servos , have a zeel now and it seems to be working . but now the stock control box is working
good point on the temp sender !

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busa1300
Posts: 282
Joined: Sat Feb 01, 2014 11:45 am
Location: N Indiana

Re: RZV500R....An attempt at turning back the clock

#8 Post by busa1300 » Thu Mar 29, 2018 8:29 pm

I checked all the fuses, and pulled them to make sure they were clean on the ends, right after I got it.....all good.
The YPVS I got in the mail today works perfect...at least for now....A Zeel may still be in the future though.
Mirrors look like new, and my box of new parts showed up so I can completely redo the wheels next week.
Then decide on tires....and get a chain too.
Going to get gas tank cleaned out this weekend, and put in my new fuel filter/outlet to petcock....then slosh some 2 stroke mix in it to keep the metal from flash rusting anymore....
Might be on the shelf for a while...?
If it's dry tomorrow I'll get the airbox/carbs off, and roll it out to powerwash everything before the wheels come off.....

Image
Last edited by busa1300 on Fri Mar 30, 2018 8:50 am, edited 1 time in total.
78 GS1000E
80 KD80
82 Katana
84 RZ350
84 RZV500R
86 GSXR1100
86 1100 sportster
88 FZR1000
89 RGV250 VJ21 SP
90 RGV250 VJ22 SP
91 TZR250 3XV2 SP
96 RGV250 VJ23 T SP
99 RS250
02 Hayabusa
16 KTM 390 Duke
17 KTM 1290 Superduke GT
21 Aprilia RSV4 1100

User avatar
nzminis
Posts: 479
Joined: Sat Aug 04, 2012 2:29 am
Location: New zealand

Re: RZV500R....An attempt at turning back the clock

#9 Post by nzminis » Thu Mar 29, 2018 9:21 pm

just did a 80km ride with the zeel fitted
feels so much crisper now , move the open rpm to 9k
think just a more modern box with slightly different values helped

520 chain conversion is well worth it , R1 front sprocket and Rz350 rear

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busa1300
Posts: 282
Joined: Sat Feb 01, 2014 11:45 am
Location: N Indiana

Re: RZV500R....An attempt at turning back the clock

#10 Post by busa1300 » Sat Mar 31, 2018 8:42 pm

I have a Zeel on my VJ23, which was way cheaper than the Sugaya R2 box that it can copy.
Definitely need dyno time to get the most out of a Zeel though....few two stroke tuners in my area....Zero....
A lot of trial and testing on the road will get it close, but few stroker owners are happy with (just close enough)
78 GS1000E
80 KD80
82 Katana
84 RZ350
84 RZV500R
86 GSXR1100
86 1100 sportster
88 FZR1000
89 RGV250 VJ21 SP
90 RGV250 VJ22 SP
91 TZR250 3XV2 SP
96 RGV250 VJ23 T SP
99 RS250
02 Hayabusa
16 KTM 390 Duke
17 KTM 1290 Superduke GT
21 Aprilia RSV4 1100

User avatar
busa1300
Posts: 282
Joined: Sat Feb 01, 2014 11:45 am
Location: N Indiana

Re: RZV500R....An attempt at turning back the clock

#11 Post by busa1300 » Sat Apr 14, 2018 12:21 pm

Hope to have engine out by end of weekend
Then finish striping frame, and check all bearings....soda blast all chassis parts and start putting back together.

Image
78 GS1000E
80 KD80
82 Katana
84 RZ350
84 RZV500R
86 GSXR1100
86 1100 sportster
88 FZR1000
89 RGV250 VJ21 SP
90 RGV250 VJ22 SP
91 TZR250 3XV2 SP
96 RGV250 VJ23 T SP
99 RS250
02 Hayabusa
16 KTM 390 Duke
17 KTM 1290 Superduke GT
21 Aprilia RSV4 1100

User avatar
busa1300
Posts: 282
Joined: Sat Feb 01, 2014 11:45 am
Location: N Indiana

Re: RZV500R....An attempt at turning back the clock

#12 Post by busa1300 » Sat Apr 14, 2018 9:18 pm

Image

Image

Image

Image
78 GS1000E
80 KD80
82 Katana
84 RZ350
84 RZV500R
86 GSXR1100
86 1100 sportster
88 FZR1000
89 RGV250 VJ21 SP
90 RGV250 VJ22 SP
91 TZR250 3XV2 SP
96 RGV250 VJ23 T SP
99 RS250
02 Hayabusa
16 KTM 390 Duke
17 KTM 1290 Superduke GT
21 Aprilia RSV4 1100

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Smoker
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Re: RZV500R....An attempt at turning back the clock

#13 Post by Smoker » Sun Apr 15, 2018 3:57 am

What's that on the left main frame rail? A sticker?

Looks like the frame color gets lighter near there. :smt017

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nzminis
Posts: 479
Joined: Sat Aug 04, 2012 2:29 am
Location: New zealand

Re: RZV500R....An attempt at turning back the clock

#14 Post by nzminis » Sun Apr 15, 2018 5:12 am

they did have clear protective strips on the frame rails , Thats what you will be seeing looks to be some residue left on there

are you going to soda blast the frame ? will that damage the anodizing ?

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busa1300
Posts: 282
Joined: Sat Feb 01, 2014 11:45 am
Location: N Indiana

Re: RZV500R....An attempt at turning back the clock

#15 Post by busa1300 » Sun Apr 15, 2018 9:14 am

Yea, I will soda blast the frame.
Soda blasting does not harm anodized finish....it's more like a deep cleaner.
It will take paint off, but doesn't do much for oxidization or rust....
The light area is where the original clear plastic tape was, which had become yellow and brittle (flaking off)
The circular sticker, will come off too before I blast....It's a commemorative plaque for some event from 1985 near MT Fuji.
I will leave the original dealer sticker on the rear fender though.
78 GS1000E
80 KD80
82 Katana
84 RZ350
84 RZV500R
86 GSXR1100
86 1100 sportster
88 FZR1000
89 RGV250 VJ21 SP
90 RGV250 VJ22 SP
91 TZR250 3XV2 SP
96 RGV250 VJ23 T SP
99 RS250
02 Hayabusa
16 KTM 390 Duke
17 KTM 1290 Superduke GT
21 Aprilia RSV4 1100

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