Operation: RZ350N REVIVAL - Florida 1985 48H Project

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TwoStrokeNut
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Operation: RZ350N REVIVAL - Florida 1985 48H Project

#1 Post by TwoStrokeNut » Fri Aug 16, 2019 3:02 pm

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”RZ350N REVIVAL” INTRO and TASK LIST...

(Edit: I’ve moved the TASK LIST here to serve as the thread index)

TASK LIST

REVIVAL Phase 1 (Started 08-10-2019)

CHASSIS
Go to Repair C01 - Replace fork seals and boots
Go to Repair C02 - Clean fuel tank
Go to Repair C03 - Clean fuel fill cap
Go to Repair C04 - Add missing 1/4” pinstripe to solo tail fairing
Go to Repair C05 - Rebuild front brake master cylinder
Go to Repair C06 - Rebuild front brake calipers
Go to Repair C07 - Replace front brake hoses, fill, and bleed
Go to Repair C08 - Rebuild rear brake master cylinder
Go to Repair C09 - Rebuild rear brake caliper
Go to #1 or #2 C10 - Replace rear brake hose, fill, and bleed
Go to Repair C11 - Clean chain/sprockets
Go to Repair C12 - Install gear shift lever
Go to Repair C13 - Grease steering head
Go to Repair C14 - Paint inside of front fairing
Go to Repair C15 - Paint inside of chin fairing
Go to Repair C16 - Paint inside of side covers
Go to Repair C17 - Paint underside of fuel tank
Go to Repair C18 - Paint inside of tail fairing (STD)
C19 - Paint inside of tail fairing (Solo) (moving to Phase II)
Go to Repair C20 - Re-cover extra seat pan
Go to Repair C21 - Replace front and rear brake pads
Go to Repair C22 - Replace front YAMAHA decal
Go to Repair C23 - Clean up Footpeg mounts
Go to Repair C24 - Clean up Reflectors
Go to Repair C25 - Trial fit of OEM optional luggage rack
Go to Repair C26 - Create and install toolkit
Go to Repair C27 - Install front fairing trim

ELECTRICAL
Go to Repair E01 - Test stator and pickup coils
Go to Repair E02 - Replace battery
Go to Repair E03 - Test ignition coil
Go to Repair E04 - Test regulator/rectifier
Go to Repair E05 - Clean up LH switchgear
Go to Repair E06 - Clean up RH switchgear
Go to Repair E07 - Install side stand switch boot
Go to Repair E08 - Paint horns
E09 - Re-key to one common key code (moving to Phase II)

ENGINE
Go to #1 or #2 or #3 M01 - Free up engine and inspect
Go to Repair M02 - Replace air filter element
Go to Repair M03 - Carb cleaning and rebuild
Go to #1 or #2 or #3 M04 - Fuel valve cleaning and rebuild
Go to #1 or #2 M05 – Adjust/Replace reed cages
Go to Repair M06 - Fix/Replace oil dipstick
Go to Repair M07 - Decarbonize YPVS spools, head, and pistons
Go to Repair M08 - Clean cylinder bores
Go to Repair M09 - Measure cylinders and pistons
Go to Repair M10 - Paint cylinders, head, and exhaust flanges
Go to Repair M11 - Remove engine from frame
Go to Repair M12 - Inspect clutch
Go to Repair M13 - Split cases and clean/inspect
Go to Repair M14 - Replace crankshaft and seals
Go to Repair M15 - Assemble engine cases
Go to Repair M16 - Clutch side assembly
Go to Repair M17 - Stator side assembly
Go to Repair M18 - Power Valve installation
Go to Repair M19 - Piston and Cylinder installation
Go to Repair M20 - Engine installation
Go to Repair M21 - Cylinder Head installation
Go to Repair M22 - Replace coolant hoses
Go to Repair M23 - YPVS System installation and adjustment
Go to #1 or #2 M24 – Test engine leak-down
Go to #1 or #2 M25 – Test engine compression
Go to Repair M26 - Install carbs
Go to #1 or #2 M27 - Fuel line installation
Go to #1 or #2 M28 - AutoLube hose installation
Go to Repair M29 - Fluids and Plugs
Go to Repair M30 - Paint expansion chambers
Go to Repair M31 - Repack silencers
Go to Repair M32 - Eliminate tachometer whine
Go to Repair M33 - Remove play from shift lever
Go to Repair M34 - Install new piston rings
Go to Repair M35 - Compression and Leak-Down Tests (Again!)
Go to Repair M36 - Install new clutch springs
Go to Repair M37 - Install larger main jets (Mikuni VM4/042/260)
Go to Repair M38 - Install cooler spark plugs (NGK BR9ES)
Go to Repair M39 - Replace coolant

REVIVAL Phase 1 Grand Total: US$1,460 (Completed 11-06-2020)

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PHASE 2 (Started XX-XX-XXXX)

CHASSIS
C50 - Install OEM swingarm
C51 - Install OEM gold rear rim
C52 - Install OEM gold front rim
C53 - Install new seat cover
C54 - Repaint bodywork
C55 - Apply OEM decals
C56 - ??

ELECTRICAL
E50 – Test catalyzer light on dash (not sure how though)
E51 - ??.

ENGINE
M50 - Try OEM catalytic exhaust system and smog parts (US)
M51 - Try OEM non-catalytic exhaust system (Canadian)
Go to Info M52 - Try 28mm Mikuni TM carbs
M53 - ??

PHASE 2 Grand Total: US$XXX (Completed XX-XX-XXXX)

.

INTRODUCTION

With the restoration of my RZ500 mostly behind me (RZ500 thread), I thought it might be the right time to introduce the 500 to her little 350 sister. And this is where the next chapter in the life of my RZ350 begins. For the first time ever, the RZ500 and RZ350 sat in the same room together!

The RZ350 had been in storage for about 8 years, so bringing her back to life isn’t just a matter of dumping some gas in her and off I go.

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A little history before I get started

I went into detail on my 2-stroke street bike history in my RZ500 thread, so I won’t repeat all that here. But I’ll give you a few more details on my involvement in this particular bike’s history.

I had wanted an RZ350 badly back when they were introduced to the US in 1984. I read everything I could find about them and the magazines were really getting people psyched up about their debut here in the states. I was a poor college kid, so there was no way I could afford one… but no one can stop you from dreaming. My old H1-500 and GT550 had to suffice as I lusted over those new RZ350s.

Bikes took somewhat of a backseat to my career in the mid-1990s, and I only owned the H1-500 through that period. I really didn’t ride it much and it remained at my parents place as I moved about the country following jobs. In 1998, my passion for bikes was reignited when I ran across a 1983 XL600R for a fair price. It was another one of those bikes I had always wanted, so I snapped it up. I thought it was a great choice because I could go nearly anywhere with it, and I did! My wife saw me having so much fun that she ended up buying a new DR650SE in 2001 so we could ride anywhere together, and we did! We both were totally into bikes again and life was good.

Later that year, we were out on one of our typical leisurely rides when I spotted an RZ350 sitting along the road with a For Sale sign on it. I laid on the brakes and nearly ended up with a DR650 on top of me (luckily, that DR had a lot better brakes than my XL!!!). After a little bit of harassment from the wifey for stopping so abruptly, the discussion turned to that RZ350 being my college dream bike. The owner was home and was happy to tell me everything he knew about it. He also dragged me into his house to show me a wall-hung portrait of his beloved H1-500 after hearing I still had one. Once a 2-stroke nut, always a 2-stroke nut!

A price of $1,850 was settled on and that RZ350 came home with me the next day in the bed of my truck.

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Looking back at the purchase date recently, I realized it was only weeks before the fateful day in US history, September 11, 2001. I don’t remember any more, but knowing me, I must have had terrible buyer’s remorse with just having made a sizable purchase on another toy with the fate of the country (and my job!) so unknown at that point.

Here is what it looked like the first day in my possession.

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When I bought it, 34mm carbs with K&N filter pods were fitted, as well as an FZ600 aluminum swingarm. The previous owner also gave me the standard tail piece for 2-up riding, which was nice because the striping was painted on (rather than a decal) and deviated from stock positioning, but both lined up with the custom graphics.

The yellow frame (it was a pale yellow) and many other things weren’t to my liking, so I stripped it down to the frame while baggin’ and taggin’ everything. The engine ran fine so there was no need to tear into it, but everything else got a good once-over. I decided to swing more towards OEM (since OEM was the picture I had in my mind all these years anyway) and sourced some stock carbs and a complete airbox assembly. The frame was painted black and the bike was re-assembled into what the next pictures show. I called this my "PHASE 1" project on this bike. I wish I would kept better track of what I did and how much it cost, but oh well.

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I always hoped to return it to complete OEM condition someday, and between the years 2002 and 2010, I found reasonably priced catalytic chambers with all the smog parts, swingarm, front and rear gold rims, and just for good measure (because they supposedly perform well and look basically OEM), some OEM Canadian RZ chambers. This will someday become this bike’s "PHASE 2" project.

I WAS pretty religious about starting and riding it occasionally to keep it running well, but in 2011, I noticed cracked and leaking injector oil lines. At the time, I was busy building my dream workshop and this little RZ was getting neglected terribly. One year after another passed by and here I am, 8 years later with a sizeable project on my hands. This currently is what I will dub its "REVIVAL". I’m hoping it will not grow to be too large of a project!

Back to the Present Day

The first picture in this thread, as well as the following show the bike right after I pulled it from my storage trailer. I had forgotten the bike is a fairly low mileage example, and now 18 years after buying it, the mileage seems even more impressive for its age.

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After looking at its condition, I was thinking, “Okay, not too bad for sitting all these years”. That thought changed, however, the instant I tried pushing down on the kickstart lever… it wouldn’t budge!!

Before digging into it too far, I decided to give her a good wash job. Honestly, it didn’t look too much different than when I parked it away.

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To get a better feel for what I was up against, some parts had to come off… namely the carbs (which I planned to clean before I even discovered the locked engine) so I could see down in the cylinders. And that’s where she stands today as I plan my attack.

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Like always when approaching projects, I like to put a task list together to help me estimate time and cost, as well as keep me focused once executing the job. It will inevitably grow as I dig deeper into the bike, but here is what I see with a quick walkaround. I also listed some tasks I have in mind for Phase 2 when my time frees up (wishful thinking!!!).

(Edit: TASK LIST moved to beginning)

So let the games begin!!!
Last edited by TwoStrokeNut on Fri Nov 06, 2020 3:48 pm, edited 127 times in total.
RZ project bike links: Operation: MOSQUITO CONTROL BIKE-RZ500 // Operation: RZ350 REVIVAL
'72 H1-500/'75 H1-500/'85 RZ350/'85 RZ500/'01 DR650/'01 Tiger 955/'07 FJR1300

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kobra
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Location: Bay Area CA

Re: Operation: RZ350 REVIVAL - Florida 1985 48H Project

#2 Post by kobra » Fri Aug 16, 2019 3:43 pm

First page!

Can't wait to see it all back in action. I love your organization and coding your procedure lol. Keep those pics coming.

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Whymee
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Location: West Virginia, USA

Re: Operation: RZ350 REVIVAL - Florida 1985 48H Project

#3 Post by Whymee » Fri Aug 16, 2019 7:02 pm

Bravo, bravo! :smt041
Great story!
Time passes in the blink of an eye. :smt003

Keep the comments & pics coming.

I have not read your 500 thread, but I have always wanted one. To me it is the holy grail of 2T street bikes, even though what I have read it "ain't what it outta be"! :smt033
2.5 RZ350's
2018 Grom
2017 KTM 390
2017 FZ-10
1973 RT3
1974 TY250
plus many others

tacky1
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Location: Pacifica,,

Re: Operation: RZ350 REVIVAL - Florida 1985 48H Project

#4 Post by tacky1 » Fri Aug 16, 2019 7:14 pm

WoooHoooooo....... And he's off :)
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)
1984 GPZ750 Turbo
1989 VFR750R RC30

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TwoStrokeNut
Posts: 284
Joined: Thu May 16, 2019 12:43 pm
Location: Florida, USA

Re: Operation: RZ350 REVIVAL - Florida 1985 48H Project

#5 Post by TwoStrokeNut » Sat Aug 17, 2019 9:13 am

kobra wrote: Fri Aug 16, 2019 3:43 pm First page!

Can't wait to see it all back in action. I love your organization and coding your procedure lol. Keep those pics coming.
Thanks! My RZ500 thread shows how I used the task list codes to act as a hyperlink index to the thread. Each one will have a link taking you to where they are discussed down in the thread. It helps me as much as you guys!
RZ project bike links: Operation: MOSQUITO CONTROL BIKE-RZ500 // Operation: RZ350 REVIVAL
'72 H1-500/'75 H1-500/'85 RZ350/'85 RZ500/'01 DR650/'01 Tiger 955/'07 FJR1300

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TwoStrokeNut
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Location: Florida, USA

Re: Operation: RZ350 REVIVAL - Florida 1985 48H Project

#6 Post by TwoStrokeNut » Sat Aug 17, 2019 9:17 am

Whymee wrote: Fri Aug 16, 2019 7:02 pm Bravo, bravo! :smt041
Great story!
Time passes in the blink of an eye. :smt003

Keep the comments & pics coming.

I have not read your 500 thread, but I have always wanted one. To me it is the holy grail of 2T street bikes, even though what I have read it "ain't what it outta be"! :smt033
Thanks! An time seems to accelerate as I get older too! Not fair! I really don't have anything to compare it to, but many say the Gamma is a better bike in some regards. I've always been partial to Yamaha's (although I like ALL bikes!), so the RZ500 was a natural for me.
RZ project bike links: Operation: MOSQUITO CONTROL BIKE-RZ500 // Operation: RZ350 REVIVAL
'72 H1-500/'75 H1-500/'85 RZ350/'85 RZ500/'01 DR650/'01 Tiger 955/'07 FJR1300

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TwoStrokeNut
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Location: Florida, USA

Re: Operation: RZ350 REVIVAL - Florida 1985 48H Project

#7 Post by TwoStrokeNut » Sat Aug 17, 2019 9:20 am

tacky1 wrote: Fri Aug 16, 2019 7:14 pm WoooHoooooo....... And he's off :)
Yep, you gotta start somewhere! This thread will be an incentive for me to keep going on it and follow through. Plus, many helpful tips from the forum members are sure to surface as we go. Looking forward to it all!
RZ project bike links: Operation: MOSQUITO CONTROL BIKE-RZ500 // Operation: RZ350 REVIVAL
'72 H1-500/'75 H1-500/'85 RZ350/'85 RZ500/'01 DR650/'01 Tiger 955/'07 FJR1300

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TwoStrokeNut
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Location: Florida, USA

Re: Operation: RZ350 REVIVAL - Florida 1985 48H Project

#8 Post by TwoStrokeNut » Tue Aug 20, 2019 1:35 pm

Service M01 - Free up engine and inspect...

As mentioned in the Intro, the poor little 350 engine was locked from sitting so long due to my neglect. Besides trying to kick it over, I tried putting it in various gears and rocking it back and forth with no luck.

I’m guessing the first thing that happened while in storage was the petcock seals gave out and started weeping fuel. The float valves likely also gave out and allowed fuel to overflow and weep into the left cylinder (bike was leaning left on side stand entire time). There is still fuel in the left crankcase and I poured about 1/2 gallon of fuel out of the left expansion chamber.

I read about hydrolock, but that doesn’t seem to be what’s keeping the crank from turning at the moment. I believe the pistons are simply stuck in the bores.

Pulling the carbs, reed blocks and chambers off revealed this

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I decided to have a look inside the engine before tearing it apart. I have an old PC-based endoscope that I finally found a smartphone app for, so that made the job a bit more convenient.

This first picture shows a “25” on the piston top.

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I believe this means the cylinders are at the first bore over (.25mm, please correct me if I’m wrong), which I thought was a good sign. She is definitely at the low end of the spectrum for available piston sizes.

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This picture shows the crosshatching still remains from the last hone job. To me, that would indicate the top end job was not that many miles ago, but I’m no expert.

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And a couple more shots in the right cylinder.

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The next picture shows a somewhat useless image down in the crankcase of the left side. It’s not of much value, but I thought I would toss it in. At least I didn’t see any rust down there.

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In an effort to free up the pistons before pulling the jugs, I sprayed a liberal amount of penetrating oil in each spark plug hole and in the exhaust ports. I’m in no big hurry, so I will get them a shot of oil each time I visit the shop where the bike is sitting. It was time to “Throw a Wrench into the Works”. Liquid Wrench, that is!

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Next, I took a peek inside the tranny through the oil fill hole. Not too much to see in there, but everything looked good and I didn’t spot any rust. The weird thing I noticed was the plastic dipstick threads were warped, swelled, or something. A pliers was needed to unscrew it and now I can’t screw it back in. So more to come on that.

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Looking at clutch basket

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There is a lot more to come on this subject. This undoubtedly will be the most time consuming of all the tasks on my list.

M01 Total Cost: US$0.00 (Nothing yet, but unfortunately that will change!)
RZ project bike links: Operation: MOSQUITO CONTROL BIKE-RZ500 // Operation: RZ350 REVIVAL
'72 H1-500/'75 H1-500/'85 RZ350/'85 RZ500/'01 DR650/'01 Tiger 955/'07 FJR1300

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kobra
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Re: Operation: RZ350 REVIVAL - Florida 1985 48H Project

#9 Post by kobra » Tue Aug 20, 2019 1:44 pm

I wonder how the engine case managed to crack in the front there...

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TwoStrokeNut
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Location: Florida, USA

Re: Operation: RZ350 REVIVAL - Florida 1985 48H Project

#10 Post by TwoStrokeNut » Tue Aug 20, 2019 1:57 pm

kobra wrote: Tue Aug 20, 2019 1:44 pm I wonder how the engine case managed to crack in the front there...
I wondered that myself.

Perhaps it was someone prying up on the case from that nearby frame cross-tube, trying to remove the engine?
RZ project bike links: Operation: MOSQUITO CONTROL BIKE-RZ500 // Operation: RZ350 REVIVAL
'72 H1-500/'75 H1-500/'85 RZ350/'85 RZ500/'01 DR650/'01 Tiger 955/'07 FJR1300

RuZty
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Re: Operation: RZ350 REVIVAL - Florida 1985 48H Project

#11 Post by RuZty » Wed Aug 21, 2019 10:02 am

The same piece is missing on my upper case, IIRC I was seperating the cases and was quite surprised (and pissed off) when it broke as I was being careful.
The borescope pictures are great, if the dimensions are good you might get away with a light hone and not need to go up a size. For the low mileage you posted I''m surprised it's not stock bore, maybe the original owner seized it.
I had a used engine with a dipstick that wouldn't go back in, it had been cross threaded. I think they are still available from Yamaha, I got a new one last year.

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TwoStrokeNut
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Re: Operation: RZ350 REVIVAL - Florida 1985 48H Project

#12 Post by TwoStrokeNut » Wed Aug 21, 2019 2:05 pm

I know I didn't break that case because I would definitely have the little piece squirrelled away somewhere in hopes of repairing it someday. LOL

Thanks for your input... I'm hoping a hone job will do it. The previous owner didn't mention anything about a rebuild, but I don't remember asking either. But that was 18 years, so who knows what we all talked about. I don't remember getting any paperwork with it besides the title. If only bikes could talk!!!

Yep, the dipsticks are available, not too much money either. No matter how cheap they are, however, I hate spending money if something can be reused satisfactorily for just a few minutes time. I may have to look closer at mine for cross-threading. its safe to say I was the last one to screw the thing in there, and I wouldn't have forced it, I don't think.
RZ project bike links: Operation: MOSQUITO CONTROL BIKE-RZ500 // Operation: RZ350 REVIVAL
'72 H1-500/'75 H1-500/'85 RZ350/'85 RZ500/'01 DR650/'01 Tiger 955/'07 FJR1300

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kobra
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Re: Operation: RZ350 REVIVAL - Florida 1985 48H Project

#13 Post by kobra » Wed Aug 21, 2019 2:24 pm

Oh, my dip stick is also SUPER tight. Not cross threaded, threads are clean and clear. I wonder if they swell over time from oil and/or water exposure.

Maybe try gently shaving the threads down? The sealing is done by the o-ring so it could work.

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TwoStrokeNut
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Re: Operation: RZ350 REVIVAL - Florida 1985 48H Project

#14 Post by TwoStrokeNut » Wed Aug 21, 2019 2:58 pm

Swelling was my first thought. I bet 2 minutes with my thread restorer file will do the trick. Unless its some funky thread pitch... then 5 minutes with a triangular file! The dipstick looks like new otherwise, so its worth a try.
RZ project bike links: Operation: MOSQUITO CONTROL BIKE-RZ500 // Operation: RZ350 REVIVAL
'72 H1-500/'75 H1-500/'85 RZ350/'85 RZ500/'01 DR650/'01 Tiger 955/'07 FJR1300

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Evans Ward
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Re: Operation: RZ350 REVIVAL - Florida 1985 48H Project

#15 Post by Evans Ward » Wed Aug 21, 2019 4:30 pm

The billet Banshee dipsticks are a great option if originality isn’t a concern. Cheap as chips too and less than the OEM one.
84 RZ350-Toomeys,SCR milled head, stk 26 carbs,300 M, 35 P, stock regrooved needles AS 2.5 turns out,stk air box,Banshee reeds Zeel non-progr CDI,TSRL Program YPVS,alum rad,R6 shock,GV emulators w/RT springs,fork brace,Shindy steering damper.

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