Yamaha RZV500R restor. project+TSI mods from Kharkiv\Ukraine

[Pasha]

Hi everybody!!!!!

I'm not a native english speaker, so my apologize for mistakes.

First of all I want to say that i'm very happy to became a part of Yamaha rd\rz\rzv500 community. I'm 25 and since my childhood I'm fond of motorcycles, especially 2-strokes. I like motorcycles at all, but my passion is engines. Nothing can be better than 2-stroke 500cc.

Such a motorcycle is very unusual for Ukraine. A friend of mine heard that approximately 10 years ago it was rd500 in Kiev (the capital). Maybe it's already dead.

My RZV is in ukraine since 1995. I'm the 4th owner. The happy owner! The previous owners were "pilots" and at last - me - the mechanic. My motorcycle needed care and kindness.

I'm working on it 1 year and 1 month. I'm very grateful rz\rd500 forum, because I had got lots of advices, while reading.

It was very hard to find out where can i get spares. Online shopping is not so popular in Ukraine yet, but I found "Yambits" and a friend of my ex. groupmate halped me to by all I needed

[Duca]

Welcome and thanks for the pics. Can never get enough pics

[Gary Papesh]

Welcome Pasha! I believe you are our first Ukrainian member here. Thanks for showing us your project.

[Ronnie]

Yeah, welcome to the group, but he'd better watch out for that snow. That'll do the bike no good at all

[RC45]

It appears RZV's find their way to all corners of the globe.

BTW, be aware the picture host does have some NSFW images around the borders of the photos if you do view the detailed shot.

[Pasha]

It was a long way for the victory.











I have painted rims for two times. Firstly, they were powder coated. But the colour was horrible. Secondly - using airbrush.




Special aspect of my project are crankshafts
None of specialists in Kharkiv did not agree to help me. All I heard was: we need centering holes in centre pin and side pins. None didn't want to do the truing on prisms. But for such a crankshaft, I think, it's the only way. Couple months I collected bravery in myself to begin...





But unfortunately the first attempt was failure. Pistons went through TDC and BDC with the difference of 0.15mm (0.0059 inches). So, detonation was inevitable. I rided 10km (6.2 miles) and ones again - crankshaft thruing.
The reason for work with crankshafts was that something was chewing between piston and the head in 3rd cylinder. As a result - centre pin and botom con-rod pin bending. Pictures will be tomorrow. Honestly, I was surprised how this motorcycle operated!!! It's condition was incompatible with life.
I didn't find any intact oil seal. Oil were everywhere!!!!!!!!!

The only thing saved she. Since 1995 mileage is 5252km (3263 miles). She is lucky, she was waiting for me

[Pasha]

And, of course, I found the TSI modifications list.







Unfortunately my camera was broken at that time, so I have no pictures.

But I can say that I modified pistons, ported cylinders (but rised exhaust up to 25.5mm). Modified reed cages.









Milled heads



Milled generator cover.

[Pasha]

Now she is growling like a kitten

The only thing that shoul be done - the paint wok. But at a moment I can't understand how to recover the original. Yet.

[Pasha]

The next stage - is to design and weld the expansion chambers. I have some experience.
















These couple (Honda dio zx af35 and Cagiva mito 125) is waiting for their term.









And I want to ask for a help of RZ\RD 500 owners group.
I read a lot about Jolly Moto exp. ch., Jim Lomas exp. ch. etc., but never saw drawings and their dimensions. Could YOU be so generous to measure lengths and diameters. And in the end it will be an experiment, which will be posted here

It is some lack of knowledge and experience because of rare cylinders operates hotter.

Upper couple - TSI. I don't really like them. I think it would be better to make them a bit more shallow. (the lowest)

[HWY9CA]

Pasha

what did you come up with for final pipe design?
tricky when mounting and roughing thought frame, Joly is not the optimum good for high end .
Many options on pipe design -ask
Brian Turfey- turfey racing.
Brian TEAM TURFREY RACING 663 HEDBURG WAY OAKDALE CA - 95361. USA 209 345 - 7957. BTURFREY@AOL.CO

[Gary Papesh]

Ronnie posted:
[quote]Yeah, welcome to the group, but he'd better watch out for that snow. That'll do the bike no good at all.
Ooops, fixed typo in post. Yes indeed, snow is not good to our bikes.

[Twinsport]

Pasha,

Ive had a Jawa TS350 too!

What happened to the crankshaft? I see to different metals there. Is it steel and aluminum?

And what kind of increase in horsepower did you gain? It's not the easiest engine to modify..

[Keysdave]

Welcome Pasha, nice to see your bikes.

[Blackshaheen]

Welcome Pasha! I love the work you have done and wish you success in completing it all
Your talent exceeds my own by a long way so I look forward to more updates.

I love all the pictures. Well done!!!!!!!!!!!!!!!!!!!!!

I have an exhaust kit from Swrbrick Racing for my bike. I will try and get permission to give you the dimensions from if if it will help you.
D.

[Pasha]

Pasha,

Ive had a Jawa TS350 too!

What happened to the crankshaft? I see to different metals there. Is it steel and aluminum?

And what kind of increase in horsepower did you gain? It's not the easiest engine to modify..

Yes Aluminium to make it lighter.

Jawa 350 mod. 638 is the best motorcycle in the list of USSR motorcycles.
Yes, it's really hard to modify it's long-stroke engine. With 188 exhaust degree, two 32 carbs and my chambers it has mad explosion from 5500 up to 7200.

My Jawa project was a big training before my Yamaha project.