First and foremost, I am in need of a non-broken front fender for the TZR250 3XV front end for this project. Please notify me if you know the whereabouts of one.
This build will be documented on your favorite YouTube channel.
https://www.youtube.com/c/KensGarage1
Here is the playlist link if you would like more details on this project.
RZ350 TZR 3XV PROJECT
https://www.youtube.com/playlist?list=PLNWACuOBX5FuYcB-aMbkL3pk-YlBE-IPN
1985 RZ350 Original California Motorcycle
This was another abandoned project I collected some time ago. On 7/20/14.
(https://i.imgur.com/vPEXPdE.jpg)
(https://i.imgur.com/ryAA201.jpg)
(https://i.imgur.com/SXe2SeE.jpg)
Jumping on this project right away, I needed some silencers for those cool expansion chambers.
8/23/14 These were delivered by Frame Maker today TZMike CF Cans
(https://i.imgur.com/UtP0SWr.jpg)
And almost ten years later
12/4/23
Frame, suspension, expansion chambers, and engine rebuild/modifications were performed by Brian Turfrey about 15 years ago.
(https://i.imgur.com/QP4ngcj.jpg)
(https://i.imgur.com/79RDmg6.jpg)
(https://i.imgur.com/r8Nqauj.jpg)
(https://i.imgur.com/JuxoiDR.jpg)
(https://i.imgur.com/yPucSR5.jpg)
(https://i.imgur.com/wO1QWcX.jpg)
(https://i.imgur.com/hHft25l.jpg)
(https://i.imgur.com/ddINVUI.jpg)
(https://i.imgur.com/guf1sZM.jpg)
(https://i.imgur.com/ZNMHZLf.jpg)
And the accompanying YouTube video
12/5/23 & 12/6/23 EP2
I am in need of the following for this project:
1. TZR250 3XV Not broken front fender, color does not matter
2. 99-05 R6 no dent no rust fuel tank, color does not matter
3. 06-07 R6 seat
The motorcycle requires stripping to the frame for some mods to be done by our favorite fabricator mad scientist Frame Maker.
Some pics of the BT frame mods.
(https://i.imgur.com/UsSTDaC.jpg)
(https://i.imgur.com/goc7OIl.jpg)
Removed a bunch more parts including the engine.
(https://i.imgur.com/ZNMHZLf.jpg)
(https://i.imgur.com/bXeRITz.jpg)
Fat pipes on the right.
(https://i.imgur.com/nyBMewL.jpg)
(https://i.imgur.com/NMe0KUN.jpg)
(https://i.imgur.com/ccVIH5N.jpg)
Help!!! I need a 3XV front fender
(https://i.imgur.com/G4W0muG.jpg)
(https://i.imgur.com/pO9OG8Q.jpg)
Air tech has several TZ versions
Should mount up to the forward fork mounts... as light as they are you wouldn't need the rear two mounts as the TZR does.
Or look on auctions.yahoo.co.jp
I have seen several on there.
https://www.airtech-streamlining.com/yamaha-fairings-seats-fenders-parts/TZ2501991B.htm
Thanks!!! I followed your link. The TZ fender is not interchangeable with this TZR. Looked thru their whole list of stuff and they don't have TZR parts.
TZ 3YL fork and TZR SP fork lowers are identical, so I figured a TZ fender would mount up easy.
12/7/23 EP3
I am in need of the following for this project:
1. TZR250 3XV Not broken front fender, color does not matter
2. 99-05 R6 no dent no rust fuel tank, color does not matter
3. 06-07 R6 seat
It is well hung would you agree?
(https://i.imgur.com/Bl3B6yz.jpg)
(https://i.imgur.com/V2nKlAc.jpg)
(https://i.imgur.com/X2BCf58.jpg)
(https://i.imgur.com/JUYODFk.jpg)
(https://i.imgur.com/YroZ8nG.jpg)
(https://i.imgur.com/V8w3dvB.jpg)
12/16/23 EP4
Some cleanup of some miscellaneous parts.
(https://i.imgur.com/2QBC0rE.jpg)
(https://i.imgur.com/cSnnNnX.jpg)
(https://i.imgur.com/I2r7hlj.jpg)
(https://i.imgur.com/Y7eYF5L.jpg)
And a pre-mod meeting with Frame Maker.
:pop: I've been subscribed to your channel for a little while. I'm enjoying watching the progress. (it's motivation for my projects)
What a great resource to have Julian available to you. You're very fortunate!
Just saw there is a 3XV RS chassis for sale in the FB RZ group for a relatively affordable price.
Yes SoCal. I am extremely fortunate to have Julian as a friend. Brilliant dude he is.
12/17/23 EP5
I am in need of the following for this project:
1. TZR250 3XV Not broken front fender, color does not matter
2. 99-05 R6 no dent no rust fuel tank, color does not matter
3. 06-07 R6 seat
After a meeting at the Professor's house yesterday the boss puts his apprentice to work.
It begins looking like this.
(https://i.imgur.com/Ju5nppF.jpg)
Then goes on a weight loss program.
(https://i.imgur.com/sKlsBbN.jpg)
(https://i.imgur.com/x1stDNU.jpg)
(https://i.imgur.com/taZtFBw.jpg)
All done right?
No, needs a bit of grinding with a flap wheel. Never used one and boy what a great tool these flap wheels are.
(https://i.imgur.com/vlX4pzt.jpg)
(https://i.imgur.com/nkdEmb2.jpg)
All done right?
No, let's do a little reverse spot facing on one of the magical machines in the Professor's shop.
(https://i.imgur.com/CiK0iyy.jpg)
Left side on unit one.
(https://i.imgur.com/Y7hIPhc.jpg)
And the left side on unit two.
(https://i.imgur.com/JI02BHl.jpg)
Measure twice and cut once, right?
(https://i.imgur.com/NWcLJf2.jpg)
And a little trimming on the right side on unit one and two.
(https://i.imgur.com/xuZIiJ5.jpg)
(https://i.imgur.com/EXDN7E6.jpg)
(https://i.imgur.com/XFECOQf.jpg)
(https://i.imgur.com/A4gJTDV.jpg)
All done right?
(https://i.imgur.com/U6mIBqX.jpg)
No, let's do some more magic on another giant machine.
(https://i.imgur.com/q2EVzJP.jpg)
(https://i.imgur.com/ColAxKP.jpg)
All done right?
(https://i.imgur.com/0SH182A.jpg)
No, a final precision ream to make them holes perfect.
(https://i.imgur.com/O02HX40.jpg)
And back home safe and sound.
(https://i.imgur.com/zizN4wu.jpg)
That was a pretty cool walk thru, Ken! I can't wait to see how this bike turns out!
Thanks Eddy.
12/22/23 EP6
On a beautiful sunny December day, more grinding, sanding, filing, paint removal, at home in preparation for modifications.
(https://i.imgur.com/PciBwr4.jpg)
(https://i.imgur.com/deqkuNm.jpg)
(https://i.imgur.com/kyObD1S.jpg)
(https://i.imgur.com/4lFMdzc.jpg)
(https://i.imgur.com/P150MVs.jpg)
12/23/23 EP6 continued
Back to Julian's house where he exposes some motorcycle porn.
(https://i.imgur.com/HPjBZGu.jpg)
And the parallel project he is working on. With paparazzi cameramen all around recording the activities.
(https://i.imgur.com/crgAVdA.jpg)
(https://i.imgur.com/v7YiIIM.jpg)
(https://i.imgur.com/zTQf3lm.jpg)
A well-deserved lunch break.
(https://i.imgur.com/4ytdAIs.jpg)
And back to work with a different rear end set up than what he is doing to mine.
(https://i.imgur.com/HOhlMrm.jpg)
(https://i.imgur.com/Du4GS6r.jpg)
(https://i.imgur.com/40CxJ59.jpg)
A fixture used for locating and checking fitment of various components.
(https://i.imgur.com/aX0WQCF.jpg)
(https://i.imgur.com/45FDeyk.jpg)
(https://i.imgur.com/ICiy1Sq.jpg)
(https://i.imgur.com/TWxM8pM.jpg)
And back to the red frame.
(https://i.imgur.com/d0cmDZt.jpg)
Very cool Ken!!
Thanks Tim. Much appreciated!!!
12/28/23 EP7
The tapered bearing races in the steering head require removal for powder coating the frame. I always put a nice little slot in the inside of the steering head above the races so that they can be removed after installation if required, BEFORE THEY ARE INSTALLED. This was not done on this frame after the ball bearing races were removed and before the tapered bearing races were installed.
I used my porting tool to very carefully grind behind the races 180 degrees apart just enough to get a drift in to knock them out.
(https://i.imgur.com/S05Nek6.jpg)
Not having ground out the groove before the races were installed...I had to clamp the drift to keep it from slipping off the edge of the race.
(https://i.imgur.com/HhhfxkG.jpg)
Success. And after removal finished grinding proper race removal slots.
(https://i.imgur.com/Hj6UK1y.jpg)
(https://i.imgur.com/nWHtBGS.jpg)
12/30/23 EP8
Front wheel clean up. Removing the rotor bolts revealed a rather strange situation. While these bolts were clearly blue loctited where the threads would contact the wheel, they also had a very hard plastic material on them close to the head.
(https://i.imgur.com/r4eOVo2.jpg)
(https://i.imgur.com/nHs6n9F.jpg)
This material was extremely hard and difficult to remove. It needed to be removed because the bolts would not drive all the way back in without binding. I tried using a heat gun which helped but this was going to take hours. Next, I clamped a nut into the vice and drove the screws in and out until all of the plastic material was removed. Here are some samples when I was chipping it off manually.
(https://i.imgur.com/32KEhNR.jpg)
I have never seen this much Loctite (or something) applied to a bolt.
The front wheel is now cleaned up and the rotors are back on the wheel ready for preliminary assembly.
(https://i.imgur.com/kt9nwIe.jpg)
1/6/24 EP9
It is time for some reassembly. Julian has a bunch of parts that he has designed and ordered enroute so this little project bike needs to become a roller.
(https://i.imgur.com/pxfwhjv.jpg)
(https://i.imgur.com/U4D5Uip.jpg)
(https://i.imgur.com/HLV2DPz.jpg)
(https://i.imgur.com/U8m64zC.jpg)
(https://i.imgur.com/BYsCjWv.jpg)
There is no upper shock mount at the moment. So, the swingarm is flopping around. Do you see that custom component jammed between the swingarm and the frame? I designed that. And it is working quite well.
(https://i.imgur.com/G1kRxid.jpg)
(https://i.imgur.com/QFMdoA1.jpg)
1/7/24 EP10
Back to Julian's shop. Here he is measuring the angle of the swingarm. And as it turns out the piece of 2 x 4 needed a very slight trim to get the attitude of the suspension where it needs to be.
(https://i.imgur.com/NFgSaVH.jpg)
Next up is getting the bike into the shop for a bit of welding.
(https://i.imgur.com/dZTuRhR.jpg)
Forward tank mount parts are fixtured and ready to be tack welded onto the frame.
(https://i.imgur.com/L1SEh65.jpg)
When I grow up, I want to learn to do this.
(https://i.imgur.com/2FE0QjW.jpg)
And trailer the thing home for a little more paint removal and test fitting of the fuel tank.
(https://i.imgur.com/SMEbZfU.jpg)
This week Julian is going to work on utilizing these cool parts that just arrived to assemble a couple of rear sub frames for this bike and one of his. Your hard work and brainpower are very much appreciated Julian!!!
The parts in the photo below are all designed by Julian. Files are sent to the source and this is the result. Really quite beautiful fabricated components.
(https://i.imgur.com/WZbAhdy.jpg)
Found a clean fender for sale if you still need one
https://page.auctions.yahoo.co.jp/jp/auction/t1123838097
(https://cdnyauction.buyee.jp/images.auctions.yahoo.co.jp/image/dr000/auc0502/users/1daea65ba7e2ce668246ea200684e9fa02ca652b/i-img816x612-1707097824hasopv85848.jpg)
And one more
https://page.auctions.yahoo.co.jp/jp/auction/n1124538824
Wow. Great finds, much appreciated!!! Looks like I need to sign up and then figure out if they will ship to US.
What Julian creates and accomplishes out of what appears to be a two-car garage is just amazing and embarrassing. I feel like I'm barely past angle-grinder engineering by comparison! It must be very humbling to work with him, and I am envious of you Ken.
Thanks Wade. Yep. Humbling indeed. My shop has a bench top drill press, a disc/belt sander, and a band saw. Julian has been doing this for about 4 decades. He knows his stuff.
1/27/24 EP11
Back to Julian's shop for more mods.
(https://i.imgur.com/eBHT7JK.jpg)
I got an update on some of the mods he has done to his bike.
(https://i.imgur.com/tiLgoGG.jpg)
(https://i.imgur.com/zDVSKvZ.jpg)
(https://i.imgur.com/2U1jQtl.jpg)
My bike came over looking like this.
(https://i.imgur.com/N07kYJl.jpg)
And left looking like this. Progress, eh?
(https://i.imgur.com/mTO5D7I.jpg)
Beautiful work Ken :patriot: :patriot:
As always impressive and encouraging work. Good luck! :metal:
Appreciate the comments fellas!!!
1/28/24 & 2/2/24 EP12
Stopped by Julian's house to look at some progress on his bike.
(https://i.imgur.com/OllVTEZ.jpg)
Back home reassembled the chassis back to a roller.
(https://i.imgur.com/GFoqZBa.jpg)
And then assembled a dummy engine for fitment of more parts.
(https://i.imgur.com/mRrEbxW.jpg)
2/10/24 EP13
Stopped by Julian's.
He was doing some bending of parts and machining tubing of subframe parts.
(https://i.imgur.com/EYAI1sb.jpg)
More send/cut/send parts arrived. Many thicker gauge "special" parts that he designed and ordered for my bike.
(https://i.imgur.com/kbrNNwY.jpg)
It's gonna be great end result. That swing-arm looks neat.
Thanks skyline
2/11/24 EP14
Frame Maker welding, assembling, and installing a master piece of metal work on Super Sunday. And a "solution" for the upper shock mount is designed.
2/19/24 EP15
Engine disassembly begins.
Taking squish band measurement.
(https://i.imgur.com/XtHlg1d.jpg)
A rare shot of the rookie mechanic in Ken's Garage
(https://i.imgur.com/1RvyA0S.jpg)
(https://i.imgur.com/547bxFj.jpg)
2/25/24 EP16
Back to Frame Makers to install upper shock mount brackets.
(https://i.imgur.com/GB27lZT.jpg)
(https://i.imgur.com/sV4jvWU.jpg)
Things went swimmingly until we tested the rear suspension. It barely moves. Julian has determined that the heavy aluminum lower arm (fabbed and set up buy someone else) is too short. The suspension is unable to work properly and will need further mods. Damn.
(https://i.imgur.com/Wd7qxmB.jpg)
I compared my RZ350 swing arm to my 3XV-SP swing arm, and the 3XV is basically 4 inches longer... wondering how that extra wheel base will change its handling? Although the 3XV bits are basically bomb proof compared to the RZ front and rear, and definitely will give more control.
Bike looks great so far :thumbs:
Thanks busa1300. It's coming along. And long wheel base for sure. Some day I'll see how it rides and handles. :vroom: