kpke RZ500 resto/mod

Got a customizing or restoration project? Post your progress pictures and updates here

Moderator: rztom

Message
Author
rd84
- - - - -
- - - - -
Posts: 1618
Joined: Thu Nov 17, 2005 7:12 am
Location: Leicestershire, UK

Re: kpke RZ500 resto/mod

#151 Post by rd84 » Tue Apr 07, 2015 6:48 am

Congratulations - looks great !!

Cheers
Paul

User avatar
Kalim
Posts: 263
Joined: Tue Aug 14, 2007 2:14 pm
Location: France - Nantes

Re: kpke RZ500 resto/mod

#152 Post by Kalim » Tue Apr 07, 2015 10:27 am

Huge step in a 4 year project ! :smt007

User avatar
kpke
Posts: 667
Joined: Tue Nov 30, 2010 9:54 pm
Location: Livermore, CA USA

Re: kpke RZ500 resto/mod

#153 Post by kpke » Sun Apr 12, 2015 11:43 am

To get this bike off non-op I have to have proof of insurance for the DMV.

To add this bike to currently insured bikes and get a gazillion $ insurance policy I have to provide pics for the insurance guy.

After this photo shoot I am back to trimming body panels hopefully for the last time.

Oh, and off to the DMV next Thursday. Should be road legal by next weekend. :smt004

From yesterday 4/11/15.

Image


Image


Image


Image
Ken's Garage YouTube Channel :smt023
https://www.youtube.com/c/KensGarage1

1985 RZ500 (R6 suspension & body work)

User avatar
kpke
Posts: 667
Joined: Tue Nov 30, 2010 9:54 pm
Location: Livermore, CA USA

Re: kpke RZ500 resto/mod

#154 Post by kpke » Sat May 30, 2015 6:56 pm

This bike has about 200 miles on it now. :smt001

I did foul the plug on the upper right last time out :smt010


But I am trying to solve this issue right now

When I modified the harness quite some time ago somehow I ended up not using the self canceling unit. I don’t remember why I left that part out. I did leave all of the wires in the harness so that I could put the self canceling unit back in if I needed to. Also to get the blinkers to work I did tie together the yellow/red and yellow/black wires in the harness together.

I have LED blinkers and a solid-state flasher unit and the blinkers will work if I keep the bar switch pushed on to the left or right. As soon as the switch is released and comes back to the center position the blinkers shut off.

I need the blinkers to stay on for some period of time when they are switched on. I believe the reed switch in the stock instrument cluster provides some sort of distance traveled in order to shut off the blinkers.

So today I put the self canceling unit back in and wired it up per the schematic hoping that this might solve this dilemma. The blinkers did not work at all, they did not turn on, nothing. There is power and ground to the brown and black wires. If I jumper the yellow/red and yellow/black wires together at the self canceling unit they work the same as if it wasn’t even there.

Before

Image


After

Image



While I am typing this I decided to go on the Internet found this

http://www.amazon.com/Signal-Dynamics-M ... B0039X2PQM

But I would prefer to solve this without spending the $70.

Does anyone have any suggestions for getting the turn signals to stay on for a period of time using LED blinkers and a nonstandard instrument cluster (KOSO)?

Thanks
Ken's Garage YouTube Channel :smt023
https://www.youtube.com/c/KensGarage1

1985 RZ500 (R6 suspension & body work)

User avatar
kpke
Posts: 667
Joined: Tue Nov 30, 2010 9:54 pm
Location: Livermore, CA USA

Re: kpke RZ500 resto/mod

#155 Post by kpke » Tue Oct 20, 2015 12:52 am

Here are some recent notes on this build. i'll post some photos later.

10/3/15
Last startup the bike was flowing fuel out the right side carbs. Tapping carbs would not stop the flow.

1 Removed all 4 carbs. Remove bowls. Check float height, they are ok. I adjusted one marginally. Removed pilot jets. They are clean. Remove float valves and everything looks good. Cleaned tips, orings, reassembled.
Changing main jets from 250 to 240. Hoping to reduce some of the exhaust goo coming out the four exhausts.

Other stuff to do...

2 Pull harness for wrapping and reinstall.

3 Remove clutch cover/water pump.

4 R&R clutch parts with new Yamaha plates, fibers, springs.

5 Install replacement clutch cover/water pump. All new Yamaha water pump parts. Bearing, orings, gasket, impeller.

6 Air filters have deteriorated and need replacement. Options are
A. UNI will make new ones to their PN PT-2642 $21.99 each
B. Bill Wilson will send me parts for K&N assembly. Will need some “engineering” to complete but good price. Need to verify bodywork clearances.
C. Rick Lance has a filter assembly but is not responding to my phone message. Around $220? Need to verify bodywork clearances.
7 Remove the rest of the misc brackets for powder coat



10/9/15
Dropped spare tank off at Cycle Finish for paint to match R6 blue. Maybe done in one week.



10/14/15
Last week dropped off 9 small brackets for powder coat. Received them today. Started installing but stopped due to harness needs to be pulled out for wrapping. Want to get harness wrapped before installing blue tank.
Ordered 4 replacement PT-2642 unifilters yesterday. Hopefully they will be here next week.
Made cardboard k&n filter assy based on Bill Wilsons dimensions. There are interference issues. Sent pics and note to Bill.
Still need to finish up synching carbs,



10/18/15 and last week

Pulled harness and wrapped with Scotch 2242 black tape. Very thick rubber high temp electrical tape type material. This really came out looking nice although one of those things that nobody sees.

Finished installing the 9 PC parts.

Put coolant in. Managed to overflow it just enough to have to disassemble a bunch of stuff to clean the coolant off of everything it spilled on. About 2 hours wasted.

Put gear oil in. Used Motul 10-40 dino oil due to having it in stock. Need to buy some synthetic 10-30.

Sunday PM started bike. Didn’t sound quite right. Right lower is not firing. Switched plugs and now left lower not firing. Put left lower back and replaced fouled right lower plug. Now firing on all 4.

Rode around the neighborhood a bit. Not too much as there are no air filters on. Big smiles.

Back in to driveway to do some more last minute cleanup as the bike is supposed to journey up to SF Dirtbag Challenge next Sunday. Also need to figure out why the KOSO speedo is not registering. Took a little while then found that it is possible took mount the custom brackets for the speedo pickup at the front wheel upside down. Fixed.

New clutch feels great. Real good news is no oil leaks on “new” clutch side cover and no coolant leaks on water pump with all new parts. Thanks to silverstrom for the side cover and Wilson for the center piece.

I was getting ready to put the bike away and decided to attempt to synch carbs with manometer. Earlier I had synched the carbs manually and would have thought they would have been very close. According the meter, not one of the four was even close to any of the others. It took a little bit to get the hang of it, but after a while I got all four very close. The off idle throttle response seems markedly different now, incredibly crisp. I did not ride it again. At one point I had the bike idling at about 700 RPM and it still sounded good. It is now at about 1400 RPM with all 4 carbs reading around 3 on the meter. I will use that device on some of the other bikes to see if I can synch them up.



10/19/15

Emailed unfilter to check on order placed last Tuesday for 4 new “mad beaver” filters. Received email later in the day that they shipped today (from So Cal) so I should have them by Wednesday. Then I can put them on and mount the fairings up and be ready to ride this weekend. I hope they get here!!!

Still working with Wilson on a K&N solution for the stock carbs.

Maybe the freshly painted blue tank will be ready for pick up this week but not holding my breath.
Ken's Garage YouTube Channel :smt023
https://www.youtube.com/c/KensGarage1

1985 RZ500 (R6 suspension & body work)

User avatar
kpke
Posts: 667
Joined: Tue Nov 30, 2010 9:54 pm
Location: Livermore, CA USA

Re: kpke RZ500 resto/mod

#156 Post by kpke » Tue Oct 20, 2015 12:59 am

Batch of 9 small parts to PC. All of these parts are now reinstalled.

Image


Image
Ken's Garage YouTube Channel :smt023
https://www.youtube.com/c/KensGarage1

1985 RZ500 (R6 suspension & body work)

User avatar
kpke
Posts: 667
Joined: Tue Nov 30, 2010 9:54 pm
Location: Livermore, CA USA

Re: kpke RZ500 resto/mod

#157 Post by kpke » Tue Oct 20, 2015 1:10 am

Clutch, cover , water pump

This has always been an eye sore, a thorn in my side when I looked at it.


Image


Walnut blasting aluminum

Image


Spare water pump parts

Image


New clutch parts from the spare parts bin

Image


Image


Image


Image


Finished product

Image
Ken's Garage YouTube Channel :smt023
https://www.youtube.com/c/KensGarage1

1985 RZ500 (R6 suspension & body work)

User avatar
kpke
Posts: 667
Joined: Tue Nov 30, 2010 9:54 pm
Location: Livermore, CA USA

Re: kpke RZ500 resto/mod

#158 Post by kpke » Tue Oct 20, 2015 1:13 am

electrical pics...maybe tomorrow :smt006
Ken's Garage YouTube Channel :smt023
https://www.youtube.com/c/KensGarage1

1985 RZ500 (R6 suspension & body work)

Rufus
Posts: 100
Joined: Thu Jan 03, 2008 5:25 am
Location: RSA

Re: kpke RZ500 resto/mod

#159 Post by Rufus » Tue Oct 20, 2015 2:28 am

Nice updates.

Clutch cover is much better!

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

Re: kpke RZ500 resto/mod

#160 Post by tacky1 » Tue Oct 20, 2015 10:45 am

Looks great Ken.. :)
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
giron
- - - - -
- - - - -
Posts: 560
Joined: Wed Nov 16, 2005 7:49 pm

Re: kpke RZ500 resto/mod

#161 Post by giron » Tue Oct 20, 2015 1:19 pm

I saw the plumbing under the tank for the fuel outlet. I took the fuel outlet from a TZR250 3MA and it works great. The fuel outlet from the TZR250 3MA has a petcock built into it. Its either on or off. Its really compact and I could never understand why Yamaha didn't do this earlier. I see that you have an oil tank under the seat. When my wife was alive she went to Japan and brought one of the tanks. RGVSteve use to make them. Its a shame that he is retiring from motorcycles.
1991 3MATZR250SP
!993 3XVTZR250SP
1996 RGV250(Lucky Strike)
1994 MC28SP
1995 MC28SP
1996 MC28SP
1985 RG500(Walter Wolfe)
1984 IT490
1985 RZV500R
1985 NS400R
1985 NS400R
1997 VFR750
1992 FZR1000
RGV400
TZR500
TZR350
1990 RZ350
1971 Porsche911S

User avatar
kpke
Posts: 667
Joined: Tue Nov 30, 2010 9:54 pm
Location: Livermore, CA USA

Re: kpke RZ500 resto/mod

#162 Post by kpke » Wed Oct 21, 2015 12:14 am

Thanks for the compliments guys.

Giron, the oil tank is from Steve. I have modified it extensively. An yes he will be missed in our MC world. The best of luck to him.

Do you have pics of the TZR fuel outlet?
Ken's Garage YouTube Channel :smt023
https://www.youtube.com/c/KensGarage1

1985 RZ500 (R6 suspension & body work)

RuZty
- - - - -
- - - - -
Posts: 367
Joined: Tue Dec 13, 2005 12:39 pm
Location: Southern Ontario, Canada

Re: kpke RZ500 resto/mod

#163 Post by RuZty » Wed Oct 21, 2015 9:51 pm

You can see one installed on the tank in the pic I posted here; http://www.rzrd500.com/500phpBB3/viewto ... 12&t=13540
IIRC they are the same bolt pattern as the RZ500 tank outlet, I have both so can verify this if you want.

User avatar
kpke
Posts: 667
Joined: Tue Nov 30, 2010 9:54 pm
Location: Livermore, CA USA

Re: kpke RZ500 resto/mod

#164 Post by kpke » Wed Oct 21, 2015 11:11 pm

RuZty wrote:You can see one installed on the tank in the pic I posted here; http://www.rzrd500.com/500phpBB3/viewto ... 12&t=13540
IIRC they are the same bolt pattern as the RZ500 tank outlet, I have both so can verify this if you want.
RuZty

If you don't mind, yes, please see if it is a bolt on. Per Giron it should be.

So that appears to be On:Off:Reserve???

If so I suppose you would mount it up and set it to reserve for running all the fuel out of the tank???

Switch it Off for removing the tank.

It would not be accessible for switching from On to Reserve while running or even parked unless the tank was lifted.
Ken's Garage YouTube Channel :smt023
https://www.youtube.com/c/KensGarage1

1985 RZ500 (R6 suspension & body work)

User avatar
kpke
Posts: 667
Joined: Tue Nov 30, 2010 9:54 pm
Location: Livermore, CA USA

Re: kpke RZ500 resto/mod

#165 Post by kpke » Wed Oct 21, 2015 11:34 pm

Here is a bunch of before and after photos without commentary on the moving of electrical components, modifying harness, the "component" tray, the battery on the underside of the tray, wrapping the harness, etc.


Image


Image


Image


Image


Image


Image


Image


Image


Image


Image


Image


Image


Image


Image


Image


Image


Image


Image


Image


Image


:smt006
Ken's Garage YouTube Channel :smt023
https://www.youtube.com/c/KensGarage1

1985 RZ500 (R6 suspension & body work)

Post Reply