(https://i.postimg.cc/vZSPNjCv/20250604-153806.jpg) (https://postimg.cc/5XLqHP4H)
Disassembly begins.
Did somebody say 421? :taz: :pop:
Yep. Athena based. Wicked pipes. Not sure which carbs yet.
All-inclusive 421 kit made for RZs ordered from AZ quads. Supposed to be here Thursday. Pipes from Wicked are next, then decide on carbs. Leaning towards 36 MM Lectrons or Smart Carbs, but damn they are pricey...
Disassembly continues.
After further study and a consultation with M in SC looks like Kehin PWK...
(https://i.postimg.cc/tCCG0Syc/20250611-134648.jpg) (https://postimg.cc/qgY5yGNc)
Kit arrived today. This version has the temp sensor hole for use in a RZ. Also coordinated with Gary (Arrow) on the RD LC Crazy forum in the UK to do his magic 421 pump rebuild and upgrade.
Love to see what you're doing with this! Keep us informed.
Arrow is the man for pumps.
Snagged a set of new Keihin PWK 35s set up for this build. If I can ever get Roger on the phone, I will order the big bore stainless steel pipes. Research indicates center stand has to come off.
I think you will like the way those PWK carbs work, I have these on my RD400 engine and cannot believe how hard it pulls from just above idle on through the RPM range.
I am looking forward to it.
For what it's worth I Purchased my pwk carbs from F.A.S.T farm and sand toys. Good experience with them. Lots of banshee items , a lot of which will work with RZ as you already know. good prices
Order placed for Wicked stainless steel big bore hybrid RZ up pipes. 3 week lead time :celebrate: :celebrate:
:clap: Woo-hoo!
:whoop: :whoop: :taz: :taz:
Quote from: Kawtriplefreak on June 16, 2025, 07:21:36 PMOrder placed for Wicked stainless steel big bore hybrid RZ up pipes. 3 week lead time :celebrate: :celebrate:
That is quick. Lead time on the Ohaz pipes for my TDR is 3 months.
Yeah they are very busy. It remains to be seen if 3 weeks is reality. Either way I am in no hurry.
(https://i.postimg.cc/66Dcgs7P/20250617-173333.jpg) (https://postimg.cc/9zYywnYP)
Disassembly continues. Rotor and stator off. Exhaust and top end off. Found one power valve retainer missing in action and a Wiseco crank.
(https://i.postimg.cc/L5fFFrzV/20250617-173117.jpg) (https://postimg.cc/5QxRwKKH)
Nothing some muratic acid and the next overbore won't fix. The pistons are marked .50 so 2nd oversize. These cylinders will be oiled, placed in zip-lock baggies and stored in my hoard along with the head.
(https://i.postimg.cc/wvC2WsJD/20250618-140420.jpg) (https://postimg.cc/k6yWGGT5)
Always afraid of losing the clutch ball... This should take care of keeping the ball and clutch rod from disappearing. Used a piece of clear hose and put the whole works in a gallon ziplock marked with direction of insertion.
(https://i.postimg.cc/wBJ7Xy6C/20250618-150108.jpg) (https://postimg.cc/Y4rrkSLR)
Have never seen a Wiseco crank
(https://i.postimg.cc/T121vtrx/20250618-150052.jpg) (https://postimg.cc/R684cQsp)
Out of the frame and nearly ready to split.
(https://i.postimg.cc/xdK1kw5Y/20250618-160051.jpg) (https://postimg.cc/06ysFHhH)
Spent a few minutes with some Gunk engine degreaser and a rag before knocking off for today. Does anyone know of an off the shelf color match for the red frame paint? This one needs some touch-up. All in all a good afternoons work.
Quote from: Kawtriplefreak on June 18, 2025, 11:57:07 PM(https://i.postimg.cc/wBJ7Xy6C/20250618-150108.jpg) (https://postimg.cc/Y4rrkSLR)
Have never seen a Wiseco crank
They had a lot of problems with the flywheel keyway machined incorrectly which threw ignition timing out the window.
i heard the same, but that bike ran great for years prior
(https://i.postimg.cc/4djMzgXX/20250620-132006.jpg) (https://postimg.cc/9RtJhs4k)
PWK 35s arrived today.
:haw: :metal: :toot: :haw:
V-FORCE 3 reeds on the way. :olaf: :olaf:
:clap:
(https://i.postimg.cc/zBfXKHck/20250623-132208.jpg) (https://postimg.cc/DWtTK0FW)
V-Force 3s arrived today. :celebrate:
Disassembly nearly complete.
(https://i.postimg.cc/Mpy7z9bX/20250625-153943.jpg) (https://postimg.cc/cvLgmMzN)
(https://i.postimg.cc/kM6Tt3xp/20250625-173550.jpg) (https://postimg.cc/c6WRVzkR)
Scrubbed and split. Transmission looks good.
PWKs disassembled. 160 Mains, 50 Pilots, CEL needle in middle clip
(https://i.postimg.cc/fLWfVsZ7/20250626-161000.jpg) (https://postimg.cc/B8yKzdjt)
Cleaned up top case. Threads chased. Bolts installed in all the holes. Clutch arm hole plugged. Bead blasted, blown clean and wiped down with acetone.
(https://i.postimg.cc/DwBQ4ZfC/20250626-161007.jpg) (https://postimg.cc/RWJJjvHf)
:clap:
Nice Progess
Slowly but surely. Next step is bake at 250 in the shop oven for an hour to get all the petroleum residue out of the metal. Then another acetone wipe down with a tack cloth and shoot some paint while it is still warm. Then, back in the oven at 200 for two hours.
Love seeing the progress and all the goodies arriving. Quite inspiring. :olaf: It's giving me motivation to keep my stuff moving, just to attempt to keep pace
(https://i.postimg.cc/3xDpjk49/20250627-152238.jpg) (https://postimg.cc/xXncnTPb)
On my last build the White RZ I bought a large metal hole saw and spent about 3 days drilling and shaping with a hand file and got a good job on the clutch cover window. And honestly I was dreading it this time around. I recently purchased some carbide Dremel cut-off wheels from Walmart of all places thier store brand and 45 minutes later all that is left to do is a little clean up with a half round hand file and it will be done. I can't believe how good this worked and very cheap as well. It was tedious but easily accomplished by cutting out the center portion vertically and then shaving down the remainder. All this was done with one cutoff wheel with a flex shaft Dremel.
(https://i.postimg.cc/XqG7MC0z/20250627-155537.jpg) (https://postimg.cc/hQnqThvL)
Gonna be a beast!! :humpty:
Thanks Fellas. I sure hope so...
i think you should chrome plate the cover. :nana:
I was thinking Pepto-Bismol pink.
pink flames on the chrome with ghost skulls at the flame tips. :metal: :haw:
Righteous :metal:
And a House of Haase Hare decal... :vroom: :vroom:
(https://i.postimg.cc/1twnmcT8/20250630-170604.jpg) (https://postimg.cc/9RXF1Tc2)
About 25 minutes with a half-round hand file and I am calling the window in the clutch cover done. Next step is to chase all the threaded holes, install bolts in them and it's off to my bead blast machine.
(https://i.postimg.cc/zDHgVYLR/20250701-140359.jpg) (https://postimg.cc/w3HvGPQ6)
Threads chased in all the holes. Bolts installed. Bead blasted and wiped down with acetone. Ready for the shop oven.
:clap: :cheers:
(https://i.postimg.cc/1zpfsPXG/20250702-152530.jpg) (https://postimg.cc/f3RwfGxy)
Just gotta chase the threaded holes and install the new transmission bearings.
:nana: :nana:
(https://i.postimg.cc/yYKHBxnf/20250703-163447.jpg) (https://postimg.cc/rzfbN8BW)
Top case is done. I have decided to leave this one unpainted since the cylinders are unpainted and the cool head is bright finished. I blew it off good and gave it a good bath with brake-kleen.
:thumbs: so clean it almost looks like you painted it white
Thanks. My 1st job in the bike shop I where I apprenticed in starting in 1977 was bead blasting. I also cleaned parts and changed tires. I have a small commercial machine I bought in 2004. It still does a good job. If I run out of things to do in retirement and live long enough I have given some thought to getting a vapor blast setup. I can be in business for somewhere in the neighborhood of 10 grand. I used to make good money glass bead blasting as a side business. Now everybody wants vapor blasting and I don't blame them, the results are phenomenal. That being said with good technique glass beads give good results.
Clean enough to eat off of :thumbs: Could leaving it unpainted make it more susceptible to staining from gas, oil, etc. that may find its way on the beautifully cleaned surface? I once had a set of RD400 wheels media blasted and the shop owner advised me to clear coat the wheels at least to keep chain lube, etc. from penetrating and sticking to the new surface. I did clear the wheels but never ending up running them on a bike to test his theory.
Sure it will get dirty over the years. But a quick wipe with a rag soaked in brake kleen will keep it looking decent. RD350 and 400 cases are uncoated.
tim did the cases on the frog. (reeded h1) after i got them back i hosed them down with wd40 and used that to clean them from there out, always looked fantastic. Only reason i get anything vapor blasted aside from carbs now is theres a local guy thats cheap and does it same day.
Yep
WD40 works great too!
(https://i.postimg.cc/CLYmBr9V/20250706-161946.jpg) (https://postimg.cc/14CpbB9W)
Duplicolor Ceramic coat caliper paint.
(https://i.postimg.cc/SND7XSWW/20250706-151843.jpg) (https://postimg.cc/nC9QgtSz)
Couldn't resist a mock-up...
Not sure why they put 347 CCs on the cylinders...
Quote from: Kawtriplefreak on July 06, 2025, 04:55:22 PM(https://i.postimg.cc/CLYmBr9V/20250706-161946.jpg) (https://postimg.cc/14CpbB9W)
Duplicolor Ceramic coat caliper paint.
(https://i.postimg.cc/SND7XSWW/20250706-151843.jpg) (https://postimg.cc/nC9QgtSz)
Couldn't resist a mock-up...
Was there a reason you went with Athena, instead if CPI or Driveline cylinders?
It all looks great to me, the cases and cylinders, great care in all your workmanship. that clutch cover looks really good. sure miss my RZ. :burnout:
Rodneya, I read a lot of good reviews on the all in one kit I bought from AZ quads and the price was right.
Thanks for the kind words. It is coming along. I hope to have the bottom end together in the next week or two. Still waiting on pipes and word on when to send the oil pump to Arrow in the UK. Realistically it will be the fall before it runs. I still have to order some incidentals too. Trying to figure out which billet intake to go with. I need to order a throttle cable for the PWKs from John at Economy Cycle and some other stuff I haven't thought of. Oh and one cylinder locating dowel that was missing when I pulled the stock cylinders. This time around I have sense enough to keep a journal to refer back to instead of trying to remember all this shit.
Quote from: Kawtriplefreak on July 06, 2025, 04:55:22 PMDuplicolor Ceramic coat caliper paint.
Couldn't resist a mock-up...
Wow, very nice! Lookin' great! :clap:
Thanks!
(https://i.postimg.cc/vBJ7CsLP/20250708-164732.jpg) (https://postimg.cc/YGxmmTPg)
Made a little more progress today.
(https://i.postimg.cc/RCwwq2TB/20250708-164839.jpg) (https://postimg.cc/YjqvsnVn)
Ordered a billet intake from Chariot performance today.
(https://i.postimg.cc/Dys7TNzf/20250718-135436.jpg) (https://postimg.cc/2Vzsd2vg)
My good friend Andy Fultz at Guard Hill Cycle spreading Yamabond #4
(https://i.postimg.cc/NjkYyrTW/20250718-152744.jpg) (https://postimg.cc/w1MnZMwV)
(https://i.postimg.cc/m2xG8Syv/20250718-164445.jpg) (https://postimg.cc/qgGY7yYw)
:clap:
(https://i.postimg.cc/02cdYgzV/20250720-132117.jpg) (https://postimg.cc/crtnWbM3)
Motor back in the frame
(https://i.postimg.cc/V6KL7FXP/20250720-132127.jpg) (https://postimg.cc/XGybqd2s)
(https://i.postimg.cc/g0Cc65zj/20250720-115515.jpg) (https://postimg.cc/bGRf7m2f)
Oil pump pulled and prepped for shipping to Arrow in the UK for rebuild/421 upgrade.
(https://i.postimg.cc/cL5FsbcX/20250721-164140.jpg) (https://postimg.cc/bZkxgLWt)
Chariot billet intake arrived today. I chose this one because you can run it with or without the internal crossover plate. Initially the plan is to set it up to run with the crossover.
(https://i.postimg.cc/RFHRyFw9/20250723-144154.jpg) (https://postimg.cc/DJ7Lb7CY)
More progress.
(https://i.postimg.cc/CKj52pdX/20250723-150358.jpg) (https://postimg.cc/zLGqLMCF)
Completely by accident going through my hoard I discovered 30MM stock Kawasaki H2 factory intake rubber clamps fit the Mikuni intake rubbers supplied with the Chariot intake.
(https://i.postimg.cc/tRm6Wy6N/20250723-155555.jpg) (https://postimg.cc/fkmkQGBV)
Clutch, kicker and counter-shaft gear reinstalled. . No adjustment was necessary.
(https://i.postimg.cc/135RRVCm/20250723-155545.jpg) (https://postimg.cc/dLpc43cp)
Stator and rotor reinstalled. The woodruff key engaged me in a battle of wills along with my bifocals but I emerged victorious.
I have the new neutral switch cover and o-ring yet to install. Then I can reinstall the chain and secure the counter-shaft sprocket. I got a goody box from John at Economy Cycle today with the rubber plugs for the cylinder water jackets and the throttle cables for the PWKs. Thanks John!
I may have missed it, and I did look, but what crank are you using for this?
Looking forward to see it and hearing it next year.
I am using a plus 4 MM Hotrods crank that came in the kit from AZ Quad parts.
I am pleased to report the oil pump is visiting the UK and has arrived at Arrow's house for the rebuild and 421 upgrade.
:clap:
(https://i.postimg.cc/xCDf75Qn/20250730-141126.jpg) (https://postimg.cc/SXdbYWjv)
Water jacket plugs installed.
(https://i.postimg.cc/PJKdCkw5/20250730-162820.jpg) (https://postimg.cc/JHyfFvxf)
Neutral switch replaced. 17 tooth counter-shaft sprocket installed. Chain adjusted.
Ring gap verified at 10 thousandths. Pistons installed. I made use of the Haase circlip security procedure with great success.
Forgive my ignorance but what be the 2 extra holes above the piston pins?
I don't know.
Thanks to M in SC for taking the time to lend his skills and expertise machining R5 banjo fittings into the Chariot intake so the carbs can be removed without disturbing the oil lines. :patriot: :patriot: you are the man!
(https://i.postimg.cc/zvDhvbJH/Resized-20250801-134125-1.jpg) (https://postimages.org/)
(https://i.postimg.cc/bwStZjjg/Resized-20250801-134147-1.jpg) (https://postimages.org/)
(https://i.postimg.cc/gkQwFB6Z/Resized-20250801-134212-1.jpg) (https://postimages.org/)
(https://i.postimg.cc/QNnC1nmy/Resized-20250801-134226.jpg) (https://postimages.org/)
:bacon:
Lovin' it! :clap: :righteous: :patriot:
https://youtube.com/shorts/RAvSDzRcDYQ?si=emIwjB7f1ALPDh6c
Gray Ghost 421 has spark! :celebrate:
Assembly pictures will follow.
(https://i.postimg.cc/SQ8kkL15/20250802-121815.jpg) (https://postimg.cc/NLgWxXc7)
Frank B came over this morning and we took his RD400 and my White RZ out for a romp through the Shenandoah National Forest to Fort Valley, VA and then we got after it. Today was top end assembly day.
Dr. Frank is depicted here putting a dab of anaerobic gasket sealer on the one piece cylinder base gasket.
(https://i.postimg.cc/C5v4Wn84/20250802-124932.jpg) (https://postimg.cc/5QCvz0nH)
We installed the supplied studs and the cylinders went on. The only hitch we encountered here was the discovery that someone had used 13 MM M8 by 1.25 nuts on the cylinders instead of 12MM so my torque adapter won't work. So we snugged them up and I ordered a 13MM torque adapter from Amazon.
(https://i.postimg.cc/9QzW366P/20250802-140104.jpg) (https://postimg.cc/bZcXkBNd)
Cool Head assembly. 1st we put the domes in place in the cylinders.
(https://i.postimg.cc/wBMMxtnr/20250802-141227.jpg) (https://postimg.cc/KKXxJYG7)
Next the o-rings were placed in the bottom half of the head and it was installed onto the cylinders and locked into the locating notches on the domes. Anerobic gasket sealer was used throughout to defy gravity while positioning the assembly.
(https://i.postimg.cc/qqV8Wfjj/20250802-141232.jpg) (https://postimg.cc/DJ6JbNVX)
O-ring installation on the studs was next.
(https://i.postimg.cc/1zVVSCgT/20250802-141355.jpg) (https://postimg.cc/1gP3cKrc) Followed by preparation of the top half of the head, more o-rings.
(https://i.postimg.cc/j5sTcCrX/20250802-173614.jpg) (https://postimg.cc/8FnxPpcJ)
This kit came with some very nice acorn nuts to secure the head. But the studs are about 1/4 inch too long for them to tighten up so it was off to the hardware store for 10 8MM 1.25 thread pitch stainless steel nylock nuts to finish the job. The head was torqued per the service manual and the Cool Head instructions to 21 foot pounds in three steps 10, 15 and 21. Many thanks to Frank B for a great day of riding and wrenching. I also informed Matt at AZ Quad Parts via email regarding the stud length in the kit.
:clap: :bacon:
(https://i.postimg.cc/Hn6WyBn5/20250805-171115.jpg) (https://postimg.cc/QKWrLgpx)
I have a bucket full of Kaw Triple signals. Today while waiting for my 13MM torque adapter to arrive I bead blasted two of them and painted them semi-gloss black. They look wide to me but they measured the same width as the factory Yamaha signals on the White RZ. They are temporary anyway as I will order some more modern shorter universal signals at some point.
(https://i.postimg.cc/HkzGsVJc/20250805-172919.jpg) (https://postimg.cc/Bjj7mZB4)
13MM torque adapter arrived.
:clap:
(https://i.postimg.cc/x16KyWCF/20250806_141052.jpg) (https://postimg.cc/dhTkJNG8)
V-FORCE 3s laid out.
(https://i.postimg.cc/FsZcN2js/20250806_141101.jpg) (https://postimg.cc/2V13x9cP)
Coolant hose from head to water pipe that extends into the clutch cover installed.
(https://i.postimg.cc/pTzh77Wv/20250806_145601.jpg) (https://postimg.cc/5Y92QsQK)
Chariot intake with crossover prepped and assembled. Anaerobic gasket sealer used to hold the o-rings in place.
(https://i.postimg.cc/43hm7Mhc/20250806_151706.jpg) (https://postimg.cc/xkn0B65j)
Intake installed with the supplied gaskets. Anaerobic sealant used throughout.
(https://i.postimg.cc/xjGgNpKB/20250806-160946.jpg) (https://postimg.cc/nMzq6kS1)
PWK 35s test fit. They will require the aftermarket throttle cable from Economy Cycle. The LH carb clears the frame (barely) and the clutch arm. The RH clears easily. The throttle cable will be rerouted.
(https://i.postimg.cc/hjXvWYKv/20250806-161021.jpg) (https://postimg.cc/8JVNLtJg)
Another view
(https://i.postimg.cc/Bv6QHzLp/20250806-160954.jpg) (https://postimg.cc/SnBhpDGY)
The new 6MM stato seals for the R5 oil banjos arrived today :righteous: :righteous:
thats too clean. throw some dirt on it
Will do
Man that is great. Sorry to derail this post. Has anybody transplanted an RZ motor in a RD frame? I know there are LC top end conversions like Marcs amazing bike but I have never seen an actual RZ motor transplants. I saw at a bike show a banshee conversion in a sport bike frame but that's it. I assume alot of fab work. excited to see how your bike turns out well done!
Quote from: gargantua350 on August 08, 2025, 09:11:42 AMMan that is great. Sorry to derail this post. Has anybody transplanted an RZ motor in a RD frame? I know there are LC top end conversions like Marcs amazing bike but I have never seen an actual RZ motor transplants. I saw at a bike show a banshee conversion in a sport bike frame but that's it. I assume alot of fab work. excited to see how your bike turns out well done!
I have a 421 RZ motor in my 73 RD. The rear engine mount was broken on the cases, so I modified the cases to fit the rd mount. The top front mount is the same, just need enlarging and I modified the bottom torsion bars to fit the side stand mounts underneath.
if I pull the 421 motor I can fit the AC motor straight back in there.
https://youtube.com/shorts/9FsgJFwsSnE?si=l-dNaMcSJCXvweVW
Most of today was spent on the throttle cables installation.
(https://i.postimg.cc/gkKX5byZ/20250812-132826.jpg) (https://postimg.cc/dLLVkXxs)
It took me about 4 hours of various combinations and experiments in routing to figure out the throttle cables. I ended up adding angled RD350 cable adjusters at the end to get the cables away from the frame rail. I was able to route the cables underneath rather than over top.Then when I did the final assembly on the throttle cable housing I discovered the throttle stop was preventing the slides from falling back to idle. I took my air drill and a burr and made it go away.
(https://i.postimg.cc/bY7W5KYp/20250812-165632.jpg) (https://postimg.cc/5jmsYKFR)
I can tell that the oil pump cable is likely too long so I will take the factory 29L oil cable out of my stock throttle cables and swap it in when the time comes.
(https://i.postimg.cc/BbP8qQn2/20250818-163904.jpg) (https://postimg.cc/0Kx5nvmN)
Peg mounts looked pretty dingy.
I didn't want to bead blast them as they weren't corroded and it takes a lot of sanding time to get something smooth enough to polish after.
(https://i.postimg.cc/28KDQFTj/20250820-151930.jpg) (https://postimg.cc/dLrpvCzg)
So I used 0000 steel wool and acetone to strip the clear coat and White Diamond metal polish with the steel wool and then a micro fiber cloth to polish.
(https://i.postimg.cc/wjrDYP2K/20250820-142210.jpg) (https://postimg.cc/WdMdM5xS)
:whistle:
(https://i.postimg.cc/8kr8hwTP/20250821-145737.jpg) (https://postimg.cc/3W7bhXyP)
I picked up a hot rod H1 triple motor for a friend of mine the other day and a set of Uni Pod filters came along with it. He gave me the Unis and they are exactly the ones I need.15 degree angle 4 inch I believe.
that should keep the barn cats from nesting in the bellmouths
Looking good. Reminds me I need to replace the foam filters on my Buffalo.
Just waiting on parts now...