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Yamaha RZV500R The 35 year quest...and other stroker stories

Discussion in 'Some Assembly Required' started by busa1300, Jan 27, 2019.

  1. busa1300

    busa1300 Been here awhile

    Joined:
    Feb 22, 2014
    Oddometer:
    419
    Location:
    Frozen North...
    Got a little work done today.....
    I forgot what a serious pain in the ass this is to do.... but I think the worst is over.

    Before
    27F48847-8959-43C3-937C-CAFDCCABCFE9.jpeg

    After... DEDD879E-D9C9-41DA-B878-B3D01434D1B5.jpeg
  2. busa1300

    busa1300 Been here awhile

    Joined:
    Feb 22, 2014
    Oddometer:
    419
    Location:
    Frozen North...
    I know it doesn’t look like much....
    But it is still progress in the right direction.

    F08DFD3A-14C5-4F87-99DE-38F38D870EFC.jpeg


    I might be able to start bolting the chassis back together soon.....still need to get swingarm machined down on each side to fit in frame yet.

    ———
  3. mentolio

    mentolio Been here awhile

    Joined:
    Jul 14, 2016
    Oddometer:
    679
    Those bolts look great, nice work (as usual). You "RZ guys" have me thinking I may need to invest some time and moolah in learning how to re-plate hardware...
    AK650 and busa1300 like this.
  4. busa1300

    busa1300 Been here awhile

    Joined:
    Feb 22, 2014
    Oddometer:
    419
    Location:
    Frozen North...
    :thumb
    It's not too difficult, but very time consuming to get them to look right.... But it's winter, so I have the time I guess.
    Fast Idle and AK650 like this.
  5. busa1300

    busa1300 Been here awhile

    Joined:
    Feb 22, 2014
    Oddometer:
    419
    Location:
    Frozen North...
    Put new bearings in the wheels, and rotors are torqued down.
    Foot controls ready to go.
    Forks rebuilt with all new oil, seals and bushings.
    All 3 calipers rebuilt and both master rebuilt.

    I’m at a bit of a financial standstill getting money around for the shock, as the money I put aside for the chassis to be done was blown on the damn dry clutch engine.

    Sorry about the really bad photo quality.....one of these days I will get a new phone....

    IMG_3252.JPG IMG_3259.JPG 9CD15E23-03E5-4061-88BD-E157C5688C3A.jpeg
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  6. busa1300

    busa1300 Been here awhile

    Joined:
    Feb 22, 2014
    Oddometer:
    419
    Location:
    Frozen North...
    Tires mounted today.
    Started drilling holes in my bolts for safety wire....another job that is a pain in the ass...
    Found a guy last Friday who said he could machine down both sides of my swing arm to the dimensions I needed to fit in the frame.
    Hopefully it will be exactly as I instructed, and maybe ready by Monday....:bow

    IMG_3284.JPG
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  7. ttpete

    ttpete Rectum Non Bustibus Supporter

    Joined:
    May 13, 2009
    Oddometer:
    7,595
    Location:
    Dearborn, MI
    Get one of these drill jigs and do it in the drill press

    https://www.pegasusautoracing.com/productdetails.asp?RecID=9718
    busa1300 likes this.
  8. busa1300

    busa1300 Been here awhile

    Joined:
    Feb 22, 2014
    Oddometer:
    419
    Location:
    Frozen North...
    I have that nut/bolt jig (on same page).....doesn't work that great at drilling the corners..... only used it a few times on my RS250 about 10 years ago....
    The one you showed looks like it would work way better....except on flange head bolts.
    Need to read the rules again and see how much more I need to drill. I might have to get that jig :thumb
  9. ttpete

    ttpete Rectum Non Bustibus Supporter

    Joined:
    May 13, 2009
    Oddometer:
    7,595
    Location:
    Dearborn, MI
    You will need to wire anything with fluid behind it including fill plugs. And anything else that you think would be a safety problem if it came loose. If you're going to track it, they may require you to run water in the cooling system. This is just a general list of things and details can vary depending on the tech person. I ran tech for AHRMA for some years.
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  10. busa1300

    busa1300 Been here awhile

    Joined:
    Feb 22, 2014
    Oddometer:
    419
    Location:
    Frozen North...
    Picked up my swing arm today.
    Needed it narrowed to fit in the frame....and my chop saw really was not the right tool for such an important pivot point.
    One man machine shop hidden in the middle of a nowhere part of town....but he got the job done exactly as need. And now I have a connection for spacers and bushings and all those bits you can’t just buy to make things work together.


    AC8F99BD-7A7A-49D7-A226-097E09C7333D.jpeg 018F22A2-43A7-4CA7-B1FF-80AAF6E11835.jpeg

    Ordering shock this weekend :happay


    ———————————————-
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  11. Cycledelic Relic

    Cycledelic Relic follow old goatpath

    Joined:
    Dec 5, 2009
    Oddometer:
    2,878
    Location:
    skinny Cen-Tex pavement
    Nice build goin on there...
    I have a friend here in Waco who owns 2 RZVs... Neither bike runs & probably never will.... He jus doesnt have the finances to get the bikes running (also an SRX6 too)
    I really wish those bikes would get the attention they need.....
    1crazypj, busa1300 and Richarde1605 like this.
  12. Richarde1605

    Richarde1605 Long timer

    Joined:
    Jan 1, 2015
    Oddometer:
    4,755
    Location:
    QLD Australia
    A somewhat sad like, but you never know?
    busa1300 likes this.
  13. busa1300

    busa1300 Been here awhile

    Joined:
    Feb 22, 2014
    Oddometer:
    419
    Location:
    Frozen North...
    Up on two wheels today....
    Although it doesn't look that much different to when I started this January.....it is cleaner along with new bearings EVERYWHERE.....
    It looks very different to what it started out when I first hauled it home before getting all the good bits.

    Only parts that are the same is the frame, axles, upper triple, handle bars, rear caliper and some bolts....

    IMG_3429.JPG

    IMG_3337.JPG


    Waiting on my Nitron shock and some sprockets.....will order my brake lines and HH pads in another week or so.....that rear shock bit a serious hole in my pocket.



    ___________________________________________________________
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  14. busa1300

    busa1300 Been here awhile

    Joined:
    Feb 22, 2014
    Oddometer:
    419
    Location:
    Frozen North...
    A few more pics since my wife let me use her phone again....:happay


    IMG_3331.JPG IMG_3333.JPG IMG_3335.JPG IMG_3339.JPG IMG_3341.JPG IMG_3344.JPG
  15. DiggerD

    DiggerD DougFir from SuperDuke Days

    Joined:
    Mar 14, 2013
    Oddometer:
    5,140
    Location:
    Mid Wet Or A Gun
    My 05 GSXR1000 needs new sneakers, imagine that!
    Looks like you have some Coniti's.
    Have not used them on a sport bike yet.

    Got any suggestions for my GSXR?

    Been riding more dirt / gravel as of late on my KTM's,, so what's the hot ticket these days For my GSXR?
    busa1300 and layzrider like this.
  16. busa1300

    busa1300 Been here awhile

    Joined:
    Feb 22, 2014
    Oddometer:
    419
    Location:
    Frozen North...
    I avoid gravel and dirt whenever possible....so no idea what works there.
    The tires I have on this latest project are Super Moto tires....design strictly for very lightweight (200/300lbs) bikes.....biggest rear is 160x60x17
    https://www.revzilla.com/motorcycle/continental-contiattack-sm-supermoto-tires
    Super sticky and not designed to take the 200hp of superbikes.....would not last long.

    Last sportbike tires I bought for a full size bike were Bridgestone RS10 tires......worked beautiful, but I think there is now a RS11 that is even better for bigger HP bikes.
    https://www.revzilla.com/motorcycle/bridgestone-battlax-rs10-tires
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  17. busa1300

    busa1300 Been here awhile

    Joined:
    Feb 22, 2014
    Oddometer:
    419
    Location:
    Frozen North...
    Dug into the trans to see what ratio's I had. The SPI has a close ratio box, the SPII has a standard ratio box.
    My lucky day as I found it had the close ratio gear set....not so great taking off from a dead start though.
    Also the SP has different locking dogs than the run of the mill RGV trans, as it is undercut from the factory.
    Need to start a new list of parts, as this dry clutch set up has a bunch of various seals that I can only get out of Japan.....I hope....


    SP trans on the right.....hard to see anything different....which can be a problem when buying online.

    dry clutch (11).JPG

    shift dogs on the SP trans...undercut

    dry clutch (5).JPG

    shift dogs on the run of the mill RGV.....not undercut

    dry clutch (6).JPG

    Also the length of the input shaft is longer on a SP trans

    dry clutch (10).JPG

    Compared to the run of the mill RGV trans

    dry clutch (9).JPG


    OK....boring info to most, but that's about all I have till I get my rear shock in the mail....or get $$$ for my brake lines.



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  18. busa1300

    busa1300 Been here awhile

    Joined:
    Feb 22, 2014
    Oddometer:
    419
    Location:
    Frozen North...
    Well .....I been removing several layers of someone else's idea of a paint job on some of the original panels that came with the bike when I bought it.
    Taking the right lower to work tomorrow to get it straightened out like the left side.
    First time I have ever seen this bike with all the bodywork on.....not my favorite.....but looks like it will cut through the air efficiently enough.


    IMG_3391.JPG IMG_3393.JPG
  19. 1crazypj

    1crazypj Absolute Genius

    Joined:
    Apr 21, 2012
    Oddometer:
    8
    Location:
    Flo-Ri-Duh
    I haven't had time to read entire thread, have you fitted cartridges into forks? They look (are?) same as (I think 1999?) GSXR600 which had same external parts as the Katana's but an internal cartridge damper in 41mm fork tubes. IIRC, they are fully adjustable and need a 'straight' spring instead of a progressive one
    busa1300 likes this.
  20. busa1300

    busa1300 Been here awhile

    Joined:
    Feb 22, 2014
    Oddometer:
    419
    Location:
    Frozen North...
    Forks are 88/89 VJ21 SP only.... 41mm fully adjustable first generation cartridge forks.
    Not the same as 600 SRAD....only thing the same to a Katana are the seals and bushings, but at a quick glance may appear similar.:thumb
    The fork tubes are even different as they are shorter than a Kat.
    Factory springs are straight rate.
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