RZV500 Restoration

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

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D6lc
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RZV500 Restoration

#1 Post by D6lc » Mon Nov 28, 2016 5:59 pm

I started my strip and restoration on my RZV500, I thought that I would document the full ongoing process on the forum, for selfish reasons so I have a full log of the work/expense should I ever come to the point of selling the bike. But also to log the process should anyone else be interested as I personally always like to read write ups on a restoration before I undertake one.

I purchased my bike a few months back, its got just over 7,300 miles on, its pretty original and clean. But shows a few marks and signs of its 30 yr life.
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Overall it’s was a great purchase.


Until I trailered it home, something I covered in a separate post…..this pic still gives me heartburn :sad:
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So the strip down process has started, spend probably 4 hrs on the bike this weekend. So far so good nothing dramatic to report, bike is nice and straight with not major issues.
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More to follow in the coming weeks/months

silverstrom
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Re: RZV500 Restoration

#2 Post by silverstrom » Mon Nov 28, 2016 6:14 pm

Looks to be quite tidy. Looking forward to watching your progress.

Have fun!

rd84
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Re: RZV500 Restoration

#3 Post by rd84 » Tue Nov 29, 2016 6:47 am

Always nice to see progress on projects.

Cheers
Paul

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jackson.40
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Re: RZV500 Restoration

#4 Post by jackson.40 » Tue Nov 29, 2016 8:33 am

Great, keep the photos coming :cool:

D6lc
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Re: RZV500 Restoration

#5 Post by D6lc » Sun Dec 04, 2016 8:01 pm

So the easy part is done, now the crappy part of the restoration, cleaning and dismantling the sub-assemblies and realizing that knackered rubber widget you cracked is no longer available!
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Seems obvious advice, but for those looking to start a full restore, take the most detailed notes you can on every bolt you remove, as well as pics
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You will be amazed when this lot comes back from the platers how many M6x20 bolt variations there are on a full bike! or which of the 5 very similar washers should you use.
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D6lc
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Re: RZV500 Restoration

#6 Post by D6lc » Sun Dec 04, 2016 8:06 pm

So it seems very obvious but wanted to ask, are both clipons straight from the factory or is the RH bar angled?

The bike I have looks perfectly straight and has absolutely no signs of crash damage, yet the RH bar is bent as you can see below:
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I only briefly rode the bike before stripping it and i didn't really notice the bar being out, so I wanted to ask the obvious before I start trying to straighten it

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phildu31
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Re: RZV500 Restoration

#7 Post by phildu31 » Sun Dec 04, 2016 9:27 pm

Hi.
The two are straight.

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Speed Freak
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Re: RZV500 Restoration

#8 Post by Speed Freak » Mon Dec 05, 2016 5:21 am

Hi,

yes they should be straight.
I also had bikes which look like new but some small bits are bent.

Best example is the CBR600RR of a friend who had an accident.

I have found a full original fairing set for him on ebay in the same color, new front fairing stay, front wheel and brake rotors straightened...
This bike also has the "used but never dropped" look now.
My bikes:
RD500 YPVS 1GE
RD350 YPVS 31K 1985
Honda CBR 1000 RR SC57
Yamaha R1 RN04

rd84
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Re: RZV500 Restoration

#9 Post by rd84 » Mon Dec 05, 2016 7:19 am

I've just had a lot of plating done - it's making my head swim just how many small variations there are in the nuts, bolts and washers which are nominally the same size - ie head shape, head type, and colour of plating - I thought Yamaha were supposed to be the masters of standardised parts ?

Cheers
Paul

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Speed Freak
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Re: RZV500 Restoration

#10 Post by Speed Freak » Mon Dec 05, 2016 12:47 pm

They have a lot of standard parts :mrgreen:

One reason why I`m so slow with my restoration...
I don`t want to do the replating step by step to save costs - but before I want to have all parts in CAD :mrgreen:

By the way, be aware of errors in the parts manual.
Like the rear shock bolts - in one parts manual (I think the 1GE) it says they are both the same part but in reality they are different.
My bikes:
RD500 YPVS 1GE
RD350 YPVS 31K 1985
Honda CBR 1000 RR SC57
Yamaha R1 RN04

D6lc
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Re: RZV500 Restoration

#11 Post by D6lc » Mon Jan 02, 2017 4:06 pm

So continuing the stripping process for the chassis parts, trying to get the parts I need plated sorted, parts needing powder coating prepped etc. I'll post more pics of the befores as I go along.

Here are some of the brakes, from 5 foot the bikes looked really good but 30yrs takes its toll
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Whilst the pistons were not totally seized, they took significant persuasion to come out!
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Yuck!
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motosapien
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Re: RZV500 Restoration

#12 Post by motosapien » Wed Sep 19, 2018 7:41 pm

D6lc wrote:So continuing the stripping process for the chassis parts, trying to get the parts I need plated sorted, parts needing powder coating prepped etc. I'll post more pics of the befores as I go along.

Here are some of the brakes, from 5 foot the bikes looked really good but 30yrs takes its toll
Image

Whilst the pistons were not totally seized, they took significant persuasion to come out!
Image

Yuck!
Image
Any updates?

D6lc
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Joined: Sun Sep 25, 2016 7:45 pm

Re: RZV500 Restoration

#13 Post by D6lc » Sat Jan 27, 2024 11:01 am

6 years on on the rebuild has finally started!!

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tacky1
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Re: RZV500 Restoration

#14 Post by tacky1 » Sat Jan 27, 2024 12:42 pm

Holy smokes. Welcome back. How is progress. Have you rebuilt the engine.
1985 RZv500
1984 RZ500 Hybrid
1986 RG500 Walter Wolf
1986 RG500 Skoal Bandit
1984 RZ350
1984 RZ350 Hybrid
1981 RD350LC
1981 RD350LC Hybrid
2009 CR500AF Supermoto 250X
2007 CR500AF 250X
1988 YSR50 (2)
1989 VFR750R RC30
1984 GPZ750 Turbo

D6lc
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Re: RZV500 Restoration

#15 Post by D6lc » Mon Jan 29, 2024 4:53 pm

tacky1 wrote: Sat Jan 27, 2024 12:42 pm Holy smokes. Welcome back. How is progress. Have you rebuilt the engine.
Haven't started that yet, wanted to get as much of the chassis back together and rolling vs another 3 totes of RZV parts!. I think I'll be doing the rebuild myself

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