Operation: MOSQUITO CONTROL BIKE - Florida RZ500 Project (52X)

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

Moderator: rztom

Post Reply
Message
Author
User avatar
TwoStrokeNut
Posts: 585
Joined: Tue Nov 20, 2012 5:12 pm
Location: Florida,USA

Re: Operation: MOSQUITO CONTROL BIKE - Florida RZ500 Projec

#91 Post by TwoStrokeNut » Thu Oct 18, 2018 2:02 pm

Service M03 - Carb Cleaning... (Part 4 of 8 )

I read a little bit about the throttle needles and it sounds like the Ron Atchison modified Mikuni 5L1 versions might be the hot ticket and I set out to make some (See thread http://www.rzrd500.com/500phpBB3/viewtopic.php?t=8030" onclick="window.open(this.href);return false; for more info). If nothing else, it would give me a reason to play on my lathe for a while.

Making the extra two .020” snap ring grooves in each needle is no easy chore, especially considering my aging eyesight. But I managed to do so, with some care and the magnifier app on my phone! The cheapest tool I could come up with was narrow kerf jigsaw blade at $5 on Amazon. I knew it was a bit wide so I shaved the teeth down a hair with a file, just on the tip.

Picture 283
Image

Here is the needle chucked up in my old Atlas lathe and the blade clamped in the tool holder. I had considered attempting this in my drill press in my home garage, but I think the precision needed is beyond the capability of holding the tool by hand.

Picture 284
Image

Picture 285
Image

Picture 286
Image

Here, the extra two grooves are on the left and I consider this a mildly successful attempt. Yeah, the groove width is slightly wider than the original, but with any luck, the clip will not be moved to either of the lower grooves during the tuning process.

Picture 287
Image

This image shows the 5L1 needle above the stock 5LT14 needle before it was trimmed to final matching length. Removing the anodizing on the tapered part would have been a much easier task if it was a different color than the base aluminum.

Picture 288
Image

Trimming it off to this length was the final step.

Picture 289
Image

Here is one of the finished 5L1 needles. I didn’t bother nipping off the top two grooves yet. I don’t believe it will be necessary to do so unless the snap ring is moved to the lowest position, in which case the top of the needle may interfere with the throttle pull linkage above the slide.

Picture 290
Image
Last edited by TwoStrokeNut on Thu Dec 20, 2018 8:18 pm, edited 3 times in total.
Project bike links: NS400R - TRIPLE THREAT // RZ500 - MOSQUITO CONTROL BIKE // RZ350 - REVIVAL
'72 H1-500/'75 H1-500/'85 RZ350/'85 NS400R/'01 DR650/'07 FJR1300/'18 Tiger 1200

User avatar
TwoStrokeNut
Posts: 585
Joined: Tue Nov 20, 2012 5:12 pm
Location: Florida,USA

Re: Operation: MOSQUITO CONTROL BIKE - Florida RZ500 Projec

#92 Post by TwoStrokeNut » Thu Oct 18, 2018 2:05 pm

Service M03 - Carb Cleaning... (Part 5 of 8 )

And finally, 4 assembled carbs awaiting installation. Undoubtedly, I will need to do a bit of tuning (I mean, I couldn’t get THAT lucky, could I?), but I decided to outfit the carbs with parts that my research has shown to be a good starting point.

Picture 291
Image

Picture 292
Image

Picture 293
Image

Picture 294
Image

Picture 295
Image

M03 Total Cost: US$121.00 (Carb kits, Float valves, Main Jets, Needles)
Last edited by TwoStrokeNut on Thu Dec 20, 2018 8:18 pm, edited 2 times in total.
Project bike links: NS400R - TRIPLE THREAT // RZ500 - MOSQUITO CONTROL BIKE // RZ350 - REVIVAL
'72 H1-500/'75 H1-500/'85 RZ350/'85 NS400R/'01 DR650/'07 FJR1300/'18 Tiger 1200

User avatar
TwoStrokeNut
Posts: 585
Joined: Tue Nov 20, 2012 5:12 pm
Location: Florida,USA

Re: Operation: MOSQUITO CONTROL BIKE - Florida RZ500 Projec

#93 Post by TwoStrokeNut » Tue Nov 06, 2018 2:02 am

Service M03 - Carb Cleaning... (Part 6 of 8 )

Before the carbs go back on, I thought it might be a good idea to do step 1 of the carb synch process, getting each side synched individually. I used some hardware wire on hand that matched the 0.7mm spec listed in the service manual. For the 1.0mm wire, I just added a couple layers of tape to it.

Picture 296
Image

You start out with the 1.0mm wire and set the cable-actuated carb to it using the idle screw, then you match the second carb to it using the synch screw. Then they get dialed in to 0.7mm slide openings. I’m not really sure why it is a 1.0 to 0.7 procedure, but it was easy enough to do. synch the second carb to the first

Picture 297
Image

Okay, the 4 nice clean carbs are ready to go back on. Not so fast! One more thing proved to be a worthwhile effort. I thought it was a good idea to see if they hold fuel because I will not tolerate leaky carbs in my garage (at least not long term). I used a clamp to hold them upright and added fuel supply and drain hoses.

Picture 298
Image

Remember those cheap repair kits I purchased? Well, even the float bowl gaskets proved to be useless. They were leaking like crazy despite having the SHC screws torqued as tight as I cared to have them. I believe the gasket material was simply too hard. It may be difficult to see the tiny embossed groove made by the crab body, but to doesn’t continue around the entire gasket. About midway between the screws, the groove fades away to nothing.

Picture 299
Image

I wasn’t about to let 4 little gaskets hold up progress, so I dug out the old gaskets removed from the carbs a couple months ago. The groove embossed into them was complete and uniform all the way around, so I thought, why not try them. Luckily, they held fuel perfectly and not a drop was seen leaking out. See, it pays to keep those old parts sometimes.

Another thing the bench test told me was that the float valves were doing their job, at least in this short test. Fuel in the hose was staying stationary after the bowls had filled up. If I would have had more time, I would have let them sit that way overnight to see if any small weeping was occurring, but I was really anxious to get this bike together.

You just have to expect a couple of setbacks when working with this stuff, so don’t let it get you down. With this behind me, it was time to install the carbs. That went without problems and here they are, back on.

Picture 300
Image

Picture 301
Image

After the throttle cables were reconnected, step 2 of the carb synch involved synching the left and right banks. At full throttle, the tab on the throttle disk is adjusted (via the opening cable adjuster) to align with the line scribed in the air snorkel mount plate on both sides.

Picture 302
Image

Picture 303
Image

At this point, the carbs are synchronized for idle opening, and full throttle opening. There is nothing really saying they will crack open perfectly synched as the two throttle “open” cables first become taunt, but I guess that’s assumed.
Last edited by TwoStrokeNut on Thu Dec 20, 2018 8:18 pm, edited 2 times in total.
Project bike links: NS400R - TRIPLE THREAT // RZ500 - MOSQUITO CONTROL BIKE // RZ350 - REVIVAL
'72 H1-500/'75 H1-500/'85 RZ350/'85 NS400R/'01 DR650/'07 FJR1300/'18 Tiger 1200

User avatar
TwoStrokeNut
Posts: 585
Joined: Tue Nov 20, 2012 5:12 pm
Location: Florida,USA

Re: Operation: MOSQUITO CONTROL BIKE - Florida RZ500 Projec

#94 Post by TwoStrokeNut » Tue Nov 06, 2018 2:16 am

Service M03 - Carb Cleaning... (Part 7 of 8 )

This bike isn’t going to run without some fuel lines and this time, I opted to spend more money than I ever have before on good Tygon ethanol tolerant type hose (F-4040-A). I really like it due to its transparency and flexibility. (Disregard the black hose pointing to the filter shown in the first picture.)

Picture 304
Image

Picture 305
Image

I originally showed some right angle filters added just below the fuel tank, but I reconsidered this approach. In order to not starve the carbs of fuel, I felt it was better to install an 8mm (5/16”) filter in each of the supply hose immediately before entering the carbs. Besides being less restrictive, the filters may catch any debris coming from the fuel valve as well (we all know those deteriorate over time!). These K&N 81-0241 are just re-branded Visu-Filters, so you might be able to save a few bucks.

Picture 306
Image

Next, the elephant ears went on, along with the choke lever and fuel valve.

Picture 307
Image

Picture 308
Image

When I purchased the larger supply hose, I also stocked up on the smaller diameter drain hose. Here is the routing of the left and right sides.

Picture 309
Image

Picture 310
Image

I didn’t route them per the OEM. Instead, I chose to collect them just past the opening in my lower fairing and angle them down so that a single jar can be used when draining the carbs. They route inboard of and are attached to the black rear shock support tubes, which should keep them far enough away from the heat of the chambers.

Picture 311
Image

Lastly, I needed to replace the supply lines between the quick disconnect fittings and the fuel shutoff valve. I used the same Tygon tubing, but with some heat sleeve since they are in close proximity to the upper exhaust chambers.

Picture 312
Image

Picture 313
Image

Note that I kept the quick disconnect fittings in place to facilitate removing the tank (make sure to buy the fitting with shutoff valves in them!!). Even if not removing the tank, fuel can be drained very quickly using a hose with the matching fitting attached. (I had to "borrow" the fitting on the downstream line because my extra set had not shown up yet.) I mated it up to the RES (reserve feed line) so most of the fuel could drain out. The other unused half of that spare fitting set could be used to build a portable fuel tank for tuning with the stock tank removed.

Picture 314
Image

Go to Part 8 showing final routing of fuel lines to carbs

M03 Total Cost: US$63.00 (Fuel Hose, Filters, Heat Sleeve)
Last edited by TwoStrokeNut on Fri Dec 21, 2018 11:36 am, edited 7 times in total.
Project bike links: NS400R - TRIPLE THREAT // RZ500 - MOSQUITO CONTROL BIKE // RZ350 - REVIVAL
'72 H1-500/'75 H1-500/'85 RZ350/'85 NS400R/'01 DR650/'07 FJR1300/'18 Tiger 1200

User avatar
TwoStrokeNut
Posts: 585
Joined: Tue Nov 20, 2012 5:12 pm
Location: Florida,USA

Re: Operation: MOSQUITO CONTROL BIKE - Florida RZ500 Projec

#95 Post by TwoStrokeNut » Tue Nov 06, 2018 2:52 am

Service M04 - YPVS Adjustment and Cable Lube...

After the carb throttle cables are adjusted, the manual says to adjust the YPVS cables next. In order to do so, I needed to find a 8mm rod. I found an 8mm or 5/16” bolt with the threads cut off worked nicely. I labeled it and it will be included in my tool kit for the bike.

You simply turn on the ignition, let the YPVS cycle, and adjust the cables so the rod fits in the fork. Cable adjusters are directly above the fork.

Picture 315
Image

Picture 316
Image

M04 Total Cost: US$0.00 (Bolt from stock)
Project bike links: NS400R - TRIPLE THREAT // RZ500 - MOSQUITO CONTROL BIKE // RZ350 - REVIVAL
'72 H1-500/'75 H1-500/'85 RZ350/'85 NS400R/'01 DR650/'07 FJR1300/'18 Tiger 1200

User avatar
TwoStrokeNut
Posts: 585
Joined: Tue Nov 20, 2012 5:12 pm
Location: Florida,USA

Re: Operation: MOSQUITO CONTROL BIKE - Florida RZ500 Projec

#96 Post by TwoStrokeNut » Tue Nov 06, 2018 2:54 am

Service M05 - AutoLube Pump Adjustment...

Following the YPVS cable adjustment, you then can move on to the AutoLube oil pump cable adjustment. The manual instructs to twist the throttle to take the slack out of the cables, and I found the pump lever moves quite a bit. You then check for alignment at two points. It’s a bit hard to get a straight on view of the pump lever, so I tried to error on the high side. A bit extra injected oil probably won’t be the worst thing for this old engine.

Picture 317
Image

Picture 318
Image

M05 Total Cost: US$0.00 (Nothing needed)
Project bike links: NS400R - TRIPLE THREAT // RZ500 - MOSQUITO CONTROL BIKE // RZ350 - REVIVAL
'72 H1-500/'75 H1-500/'85 RZ350/'85 NS400R/'01 DR650/'07 FJR1300/'18 Tiger 1200

User avatar
TwoStrokeNut
Posts: 585
Joined: Tue Nov 20, 2012 5:12 pm
Location: Florida,USA

Re: Operation: MOSQUITO CONTROL BIKE - Florida RZ500 Projec

#97 Post by TwoStrokeNut » Tue Nov 06, 2018 2:56 am

Service M09 - Replace Spark Plugs...

The old plugs weren’t bad looking, but a fresh set never hurts, right? I chose NGK Iridium BR9HIX this time. Hopefully I won’t need to replace them because they are not cheap.

Picture 319
Image

Picture 320
Image

Picture 321
Image

M09 Total Cost: US$40.00 (Spark Plugs)
Project bike links: NS400R - TRIPLE THREAT // RZ500 - MOSQUITO CONTROL BIKE // RZ350 - REVIVAL
'72 H1-500/'75 H1-500/'85 RZ350/'85 NS400R/'01 DR650/'07 FJR1300/'18 Tiger 1200

User avatar
pstamper
- - - - -
- - - - -
Posts: 1743
Joined: Fri May 09, 2008 8:56 pm
Location: Houston, Texas

Re: Operation: MOSQUITO CONTROL BIKE - Florida RZ500 Projec

#98 Post by pstamper » Wed Nov 07, 2018 3:13 pm

Great write up and pictures. Look like me with the sticky notes. Did you check the floats wi overflow lines on sides of carbs or just measurement. Keep up the great work and video on my he start up.

User avatar
TwoStrokeNut
Posts: 585
Joined: Tue Nov 20, 2012 5:12 pm
Location: Florida,USA

Re: Operation: MOSQUITO CONTROL BIKE - Florida RZ500 Projec

#99 Post by TwoStrokeNut » Thu Nov 08, 2018 9:19 am

Thanks pstamper. Gotta love those sticky-notes... At my age, I need them for nearly everything!!

I saw the float check in the manual and was planning to do it. But I guess the whole leaking gasket incident threw me off a bit and I forgot to do it. For now, I'll have to rely on the measurement check I did with the caliper when the bowls were off. When/If I pull the carbs off again to do any tuning I will give them a proper float check. Thanks for the reminder!!

Start-up video coming soon!!! (I hope!!)
Last edited by TwoStrokeNut on Thu Nov 08, 2018 2:19 pm, edited 1 time in total.
Project bike links: NS400R - TRIPLE THREAT // RZ500 - MOSQUITO CONTROL BIKE // RZ350 - REVIVAL
'72 H1-500/'75 H1-500/'85 RZ350/'85 NS400R/'01 DR650/'07 FJR1300/'18 Tiger 1200

User avatar
pstamper
- - - - -
- - - - -
Posts: 1743
Joined: Fri May 09, 2008 8:56 pm
Location: Houston, Texas

Re: Operation: MOSQUITO CONTROL BIKE - Florida RZ500 Projec

#100 Post by pstamper » Thu Nov 08, 2018 11:05 am

It is just convenient because you will know if the leak before mounting to the bike. Still I enjoy all the pictures and you definitely have a good way of explaining the process. Make me remember what I went thru. Keep the posts and great work coming.

By the way the Champion L-78 plugs are reasonable cost and have been great in all the years with both bikes, street and track. NAPA or most auto parts stores carry them.

User avatar
Smoker
- - - - -
- - - - -
Posts: 1757
Joined: Sat Jun 14, 2008 7:16 am

Re: Operation: MOSQUITO CONTROL BIKE - Florida RZ500 Projec

#101 Post by Smoker » Thu Nov 08, 2018 1:10 pm

If I haven't posted this already... THANKS!! :smt023

The detailed write-ups and good photos help owners like me a lot.

Haven't had much experience with this engine, and even simple maintenance can be intimidating.

Please keep up the good work!

User avatar
TwoStrokeNut
Posts: 585
Joined: Tue Nov 20, 2012 5:12 pm
Location: Florida,USA

Re: Operation: MOSQUITO CONTROL BIKE - Florida RZ500 Projec

#102 Post by TwoStrokeNut » Fri Nov 09, 2018 12:51 pm

pstamper wrote:It is just convenient because you will know if the leak before mounting to the bike. Still I enjoy all the pictures and you definitely have a good way of explaining the process. Make me remember what I went thru. Keep the posts and great work coming.

By the way the Champion L-78 plugs are reasonable cost and have been great in all the years with both bikes, street and track. NAPA or most auto parts stores carry them.
If you're projects go like anything like my projects, there's probably a couple of things you DON'T want to be reminded of too. LOL Thanks for the tip on the alternative plugs.
Project bike links: NS400R - TRIPLE THREAT // RZ500 - MOSQUITO CONTROL BIKE // RZ350 - REVIVAL
'72 H1-500/'75 H1-500/'85 RZ350/'85 NS400R/'01 DR650/'07 FJR1300/'18 Tiger 1200

User avatar
TwoStrokeNut
Posts: 585
Joined: Tue Nov 20, 2012 5:12 pm
Location: Florida,USA

Re: Operation: MOSQUITO CONTROL BIKE - Florida RZ500 Projec

#103 Post by TwoStrokeNut » Fri Nov 09, 2018 1:00 pm

Smoker wrote:If I haven't posted this already... THANKS!! :smt023

The detailed write-ups and good photos help owners like me a lot.

Haven't had much experience with this engine, and even simple maintenance can be intimidating.

Please keep up the good work!
Thanks for taking the time to "stop by" and pass along some kinds words.

I admit I was a bit intimidated by this engine too, mainly because of part replacement cost and rarity if something goes wrong. But I've been just trying to follow the manual and tips from this forum were I can, and relying on my bike wrenching experience for the rest. Hopefully all combine to keep me out of trouble!

More posts on the way! Our cool time of the year is coming when I tend to spend much more time in the workshop. There is a healthy dose of electrical work to do soon.
Project bike links: NS400R - TRIPLE THREAT // RZ500 - MOSQUITO CONTROL BIKE // RZ350 - REVIVAL
'72 H1-500/'75 H1-500/'85 RZ350/'85 NS400R/'01 DR650/'07 FJR1300/'18 Tiger 1200

User avatar
TwoStrokeNut
Posts: 585
Joined: Tue Nov 20, 2012 5:12 pm
Location: Florida,USA

Re: Operation: MOSQUITO CONTROL BIKE - Florida RZ500 Projec

#104 Post by TwoStrokeNut » Fri Nov 09, 2018 1:20 pm

Service E01 - Replace Battery (AGAIN!)...

With this long of a project, it seems the project outlived the battery. But at near 6 years, I guess I can’t complain about a battery dying. I picked up an even cheaper one this time. It’s the old style maintenance-type battery, but I don’t expect to be adding much water to it with its limited use, so it should be fine.

(A bit of a confession… The battery was actually replaced before I could check the YPVS adjustment, so this post is out of order.)

Picture 322
Image

Here it is with the lid/heatshield on. Oops, it looks like I forgot to hook the main fuse pack on its perch in the photo. I also need to come up with something to use as the hold-down straps because the lid “HOOK” is no longer available.

Picture 323
Image

E01 Total Cost: US$20.00 (Battery)
Project bike links: NS400R - TRIPLE THREAT // RZ500 - MOSQUITO CONTROL BIKE // RZ350 - REVIVAL
'72 H1-500/'75 H1-500/'85 RZ350/'85 NS400R/'01 DR650/'07 FJR1300/'18 Tiger 1200

User avatar
TwoStrokeNut
Posts: 585
Joined: Tue Nov 20, 2012 5:12 pm
Location: Florida,USA

Re: Operation: MOSQUITO CONTROL BIKE - Florida RZ500 Projec

#105 Post by TwoStrokeNut » Fri Nov 09, 2018 1:47 pm

THE OLD GIRL LIVES AGAIN!!!!...

It was an exciting day for me, one that had been in the works for almost exactly 6 years. I have not heard this bike run since November of 2012, on the day and the day after I bought it, after putting on that whopping 3.8 kilometers of the tripmeter. I needed some incentive to keep pushing hard on this project… I still have I lot of electrical work to do, as well as a bunch of maintenance items.

Here is sort of a blow-by-blow as it happened:

A couple gallons of fuel in, fuel valve on prime, a quick check to see that fuel is flowing down each carb supply hose. Wait, nothing! No fuel flowing. Hmmm. I hinged up the tank and squeezed the tank line a bit. This seemed to burp it and fuel was trickling down. Good to go, I thought. A few kicks with choke on and she stumbled to life. But I noticed no smoke from the upper two chambers. Better turn it off and inspect. I found enough fuel had flowed to fill the lower carbs, but the uppers were not filled. A few more pumps of that tank line and fuel seemed to be flowing nicely again and all hoses looked full now. I cracked open the bowl drain screws just to verify each received SOME fuel. Good flow out all four. Okay, let’s try this again. It fired right up. This time, it was much more responsive to the throttle. All is well. Let it warm up a bit and listen for strange sounds. None. Okay, it’s time to wake up the neighbors with this high-revving 2-stroke symphony. It was music to MY ears, anyway! I shut it off a few times and she fired up again in one medium effort kick. About half application of the choke killed it. Seems about right after it was warmed up.

Everything seemed perfect to me so it is onward with the other restoration tasks.

Picture 324
Image

Hopefully these videos open and play for you. I watch them each night before bedtime and they put a smile on my face every time. The next milestone is riding it!!

Video 325
VIDEO LINK OF BIKE RUNNING (OVERALL VIEW)

Video 326
VIDEO LINK OF BIKE RUNNING (TACH VIEW)

I drained the fuel out of the tank (because I wasn’t THAT confident), but left what was in the carbs and lines as a test to see if any drips show up over the next couple of weeks.
Project bike links: NS400R - TRIPLE THREAT // RZ500 - MOSQUITO CONTROL BIKE // RZ350 - REVIVAL
'72 H1-500/'75 H1-500/'85 RZ350/'85 NS400R/'01 DR650/'07 FJR1300/'18 Tiger 1200

Post Reply