Norwegian RD 350 YPVS hybrid build.

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TommyPettersen
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Re: Norwegian RD 350 YPVS hybrid build.

#16 Post by TommyPettersen » Fri Feb 05, 2016 8:01 am

The Engine.
My bike had a rough life. 80.000km is a lot on any bike and especially a two stroke. So when I opened up the cylinders I could see that It was on the last bore. The bore was ok, but one of the cylinders also had a piece chipped off. The head had markings of several breakdowns. I were lucky to find a very nice cylinder set still on the original bore. It did not even need a rebore.. just a hone and new rings. I had decided early on that I was not going to port, stroke or modify this engine. Money were going to be spent elsewhere. So the only upgrades is Vforce4 reeds, Keihin 28mmPWK carbs and the K2-tec pipes. I did want the engine to look special. I had the engine blocks tumble polished, to get that natural aluminum look of the early R5`s.
The cylinders and head were powder coated in wrinkle finish.
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I bought some engine covers from Matton machine.
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But I felt it were to much aluminum look so I came up with this neat little custom trick. I bought a roll of anti skid tape 100mm wide. Then cut out various shapes to keep the “wrinkle theme” on other parts as well. It matches up pretty well, I think.
After posting this on a Norwegian forum, a member told me that you can get large square sheets of anti skid tape in skateboard shops. They even sell a special cleaning stick for it.
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TommyPettersen
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Re: Norwegian RD 350 YPVS hybrid build.

#17 Post by TommyPettersen » Fri Feb 05, 2016 8:11 am

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even on other places the anti skid tape can help to keep the "theme"
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JonW
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Re: Norwegian RD 350 YPVS hybrid build.

#18 Post by JonW » Fri Feb 05, 2016 9:26 am

I like it, nice linear thinking! :)
80 XT500 Supermoto!
81 RD350LC Resto
82 RD421LC Hybrid
82 RD350LC decapitation project
82 RD250LC JDM '251LC' YPVS
83 RZ350 Resto
84 RZ500 Resto
85 RZ350 F1 Resto
86 RZ350 F2 Resto
86 RZ350 F2 Hybrid

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two-stroke-brit
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Re: Norwegian RD 350 YPVS hybrid build.

#19 Post by two-stroke-brit » Fri Feb 05, 2016 3:21 pm

HA i used to use that on my skateboard as a kid. :smt023
350LC,Athena 392 big bore,stock porting,swiss cheese air box,stock reeds,spec11 pipes.(now TSA big bore pipes)
She might not be pretty but she will always be a fun ride


1982 YAMA RD350LC
98KDX 220R
1967 TRIUMPH TIGER
2001 TRIUMPH TT600

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TommyPettersen
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Re: Norwegian RD 350 YPVS hybrid build.

#20 Post by TommyPettersen » Thu Feb 11, 2016 4:50 pm

Today I’m going to talk about radiators, and my choice of one. In my personal opinion, there are not any good-looking radiators available for the RD/RZ. Sure, you can get the aluminum version of the stock one, but it still looks dated. I think that a “rounded” radiator looks best on a hybrid. It gives a modern look. The problem is that most rounded radiators are too wide. In addition, the hose connections should be at a place that seem somewhat like the factory would have done it.
The hybrids I have seen pictures of worldwide mostly use the TZR 250 “3MA” or RGV250/RS250 or Cagiva Mito/Ducati variations.. The problems with these are that, IMO they are too wide. At aprox 40cm+/- they don’t look quite at home, making the whole build suffer. Yamaha themselves would not have fitted something that wide. In fact they never did.
I have been watching this and many other forums for years. I have been looking on ebay for radiators, counting fins to calculate how wide they are, googling specialty bikes only available in some countries, just to try finding a good one. I did find a site in Japan where one guy fits a bunch of different radiators on a RD/RZ and explains what is needed for each installation. That was helpful. I thought that I could use a TZR 250 radiator ( I found a used one) as a beginning point, and then have it sent to China or somewhere else to have it modified. I wanted that it should have aprox 60mm taken of the width. 30mm on each side. In addition, the brackets needed changing+ one of the outlets.
Here the TZR 250 radiator is shown on a RD frame. It sticks out rather far on each side.<br />In my opinion too far.
Here the TZR 250 radiator is shown on a RD frame. It sticks out rather far on each side.
In my opinion too far.
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Problem was that the Chinese would not take it. One company had problems with making “rounded” radiators as they admitted having leakage problems with them. That’s good to know…
The other company I tried could do a copy, but did not want to make my modifications.Here in Norway the radiator shops did not want to touch it at all.
On the left side the upper water outlet points straight to the frame. Not so ideal.
On the left side the upper water outlet points straight to the frame. Not so ideal.
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I had just about given up as I randomly sat searching google pictures for radiators as an interesting candidate came up. It had the size 34cmx20cm. That is exactly the width I wanted. The lower inlet was where it must be, the top one were also ok, it had 4 sturdy brackets for bolting up too.
Very nice solid looking radiator. At only 34cm wide it is really slim.
Very nice solid looking radiator. At only 34cm wide it is really slim.
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The only bad thing, as you Hawkeye’s out there will see is that the filler neck is at a less than ideal placement. I can imagine the questions if i rode around with it like that.. The radiator is actually a Gokart model meant to sit behind one of the wheels. That is why the filler neck is on the end.
Anyway, I could work my way around that. The filler neck can be removed, then welded to shut the hole. In addition, two small nuts can be welded to each end making it possible to mount some kind of fancy stainless or carbon end-cover as many modern bikes have.

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TommyPettersen
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Re: Norwegian RD 350 YPVS hybrid build.

#21 Post by TommyPettersen » Thu Feb 11, 2016 5:02 pm

However, on the negative side, welding will make the paint boil, even some distance away from the weld-place. And the paint on these are really nice. So I began to think about think about alternate solutions for the problem. After cutting away the filler neck, carefully grinding it down I could see that the hole had a rather thick edge. If I could find/make some kind of disc aprox 30mm dia… but how to mount it and get it sealed??
Here you can see what the hole looks like when the filler neck has been removed. I have made some brackets welded to the frame as well. The angle for the hose from the engine is rather nice too
Here you can see what the hole looks like when the filler neck has been removed. I have made some brackets welded to the frame as well. The angle for the hose from the engine is rather nice too
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After some measurements and searching Aliexpress… Ohh no… I found some Rizoma (china) flush mount handlebar ends. If I use them, kind of like those rubber blanks you get to plug the freeze plug holes in car engines…
Here is the China-Rizoma handlebar end i will use as a plug. The inner cone is removed and i have used some gasket sealer as well.
Here is the China-Rizoma handlebar end i will use as a plug. The inner cone is removed and i have used some gasket sealer as well.
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I removed the inner cone as I needed this to sit flush against the flange. I used some gasket sealer as well to make sure that there would not be any leakage. I have pressure tested this and it does not leak at all. With the Rizoma cap the radiator looks rather nice too. It doesn’t just look like an excuse for pluging up a hole..
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JonW
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Re: Norwegian RD 350 YPVS hybrid build.

#22 Post by JonW » Thu Feb 11, 2016 7:58 pm

Thats a very neat solution Tommy, I like it. I used a (square edge, straight) ATV rad on my LC which worked out well. I needed the extra width to catch some air, my RGV forks/wheel/guard were totally blocking the cooling on my bike.

The only issue I see here is the tanks on the ends which Ive been told can be a problem for the water flow, so interested to see what this is like when youre up and running.

Do you have a link to that site you mentioned with the fitting of the different rads? sounds interesting and not one ive seen before.
80 XT500 Supermoto!
81 RD350LC Resto
82 RD421LC Hybrid
82 RD350LC decapitation project
82 RD250LC JDM '251LC' YPVS
83 RZ350 Resto
84 RZ500 Resto
85 RZ350 F1 Resto
86 RZ350 F2 Resto
86 RZ350 F2 Hybrid

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TommyPettersen
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Re: Norwegian RD 350 YPVS hybrid build.

#23 Post by TommyPettersen » Thu Feb 11, 2016 8:28 pm

Sure i have...
This took some time to find.. There is a lot of great info in japan on these bikes..
Here you go:

https://translate.google.no/translate?s ... edit-text=" onclick="window.open(this.href);return false;





Tommy

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JonW
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Re: Norwegian RD 350 YPVS hybrid build.

#24 Post by JonW » Thu Feb 11, 2016 9:16 pm

Thanks Tommy, lots of info there as you say, well worth reading :)
80 XT500 Supermoto!
81 RD350LC Resto
82 RD421LC Hybrid
82 RD350LC decapitation project
82 RD250LC JDM '251LC' YPVS
83 RZ350 Resto
84 RZ500 Resto
85 RZ350 F1 Resto
86 RZ350 F2 Resto
86 RZ350 F2 Hybrid

Like Watches? www.PloProf.com & www.DeskDivers.com

hondaror
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Re: Norwegian RD 350 YPVS hybrid build.

#25 Post by hondaror » Sat Feb 13, 2016 1:26 pm

I have a round, stock version I could sell you. It was punched by the front wheel. I can't say it won't leak.
Rory
2 1984 RZ350s
1985 RZ350
9 1986-1990 RZ350s
2000 ST2
2005 749
2005 749 with 999 engine

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TommyPettersen
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Re: Norwegian RD 350 YPVS hybrid build.

#26 Post by TommyPettersen » Thu Feb 18, 2016 5:24 pm

Some more info and pictures on the radiator installation. Here is what it looks like in the frame:
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When connecting hoses there are some things to think about. The radiator has 19mm outlets and the engine has 22 mm. So upper and lower hoses needs to be of a stepped type. Also the oem RD radiator has two upper outlets, one for the fill neck and the other one goes to the cylinderhead. I have seen all kinds of solutions to this when fitting a radiator without filler neck. It usually involves some kind of T-fitting and an extra hose. Most of the time this doesn't look very nice. I found a nice filler neck of a zxr 400 which has 2 outlets. This will fit nicely and make for a clean installation. Here is a picture of it:
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I will also drill and install a small outlet for the small hose that comes from the cylinder head. Here you can see the filler neck where it will be sitting with the upper waterhose in place:
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TommyPettersen
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Re: Norwegian RD 350 YPVS hybrid build.

#27 Post by TommyPettersen » Thu Feb 18, 2016 5:36 pm

Here is two more pictures showing the radiator with the lower hose in place. The angle of the radiator is a near perfect fit with the 45 degree hose:
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Here seen from the top, the hose actually points a little inwards making it look stock:
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JonW
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Re: Norwegian RD 350 YPVS hybrid build.

#28 Post by JonW » Thu Feb 18, 2016 6:23 pm

That looks very neat now its all fitted Tommy.
80 XT500 Supermoto!
81 RD350LC Resto
82 RD421LC Hybrid
82 RD350LC decapitation project
82 RD250LC JDM '251LC' YPVS
83 RZ350 Resto
84 RZ500 Resto
85 RZ350 F1 Resto
86 RZ350 F2 Resto
86 RZ350 F2 Hybrid

Like Watches? www.PloProf.com & www.DeskDivers.com

seahorse
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Re: Norwegian RD 350 YPVS hybrid build.

#29 Post by seahorse » Thu Feb 18, 2016 6:49 pm

Looking good.
It will pay to temporarily fit the front tipples, forks and wheel to check clearances.
I'm guessing your steering stops will need to be modified if you haven't already done so.
81 RD 250 LC Hybrid .Widened frame with Aprilia RS250 Back end & Front end, strokd RZ 421, Kennys TSA's, 31KVM26SS Carbs M-360 P-25 ALBA Ndl Pos 3, Air 1.3/4
81Rd350lc resto 2016
81 Rd250lc resto 2017
1999 ZRX 1100

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TommyPettersen
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Re: Norwegian RD 350 YPVS hybrid build.

#30 Post by TommyPettersen » Thu Feb 18, 2016 6:56 pm

yup, already done... :smt003

Thanks for mentioning though..

it is a combined steering stop and steering damper bracket:
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