RZ/RD 350 & Misc. 2-Stroke Tech BBS

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PostPosted: Thu Mar 02, 2017 3:19 pm 
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Progress on the project has been slow, but things are starting to come together.

The base gaskets lined up almost exactly with the transfer openings in the cylinders.

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The transfer openings in the upper engine case are much smaller.

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After a few hours of gringing and sanding, the upper case openings are now matched to the transfers in the cylinder.

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According to the parts fiche at Boats.net, the RZ350 and the Banshee use the same fiber clutch plates.
However, EBC lists different clutch kits for the RZ and Banshee.
EBC CK2240 - RZ350
EBC CK2279 - Banshee

I happened to have both clutch kits at the shop, so I opened them up to have a look.
It turns out that the Banshee fibers have more surface area than the RZ, so I'm going to use the Banshee clutch in the new engine.

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A few weeks ago I had to push the bike out of the garage, so that I could get a new hot water heater into the basement.
It was around 50*F that day, and I thought about going for a short ride.
Then I almost dropped the bike on the slippery ice in the driveway, and said f*ck that, as much as I'd like to ride, it's not worth the risk.

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Pushed the bike back into the garage, and went back to work on the motor.
The bottom end is all back together with the new crank and new oem seals.
The paint on the upper engine case is not too bad.
There are a few marks and scuffs on it, but I didn't bother to paint it.
I'm not a very good painter and I figured the oem paint would look better than the crap paint job that I would do.

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I did paint the cylinders. They've been bored and honed and are ready to be installed.

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The clutch cover that I have was all beat to hell. Lots of scratches and chips in the paint. So I had to paint it.
The paint went on a lttle thick, and you can still see a few small marks in it.
It's definitely not mint, but it's way better than it was.

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Now that I've finished all the dull, tedious work, it shouldn't take very long to finish putting it back together.

- Install oil pump, water pump and new seals in the clutch cover
- Install new pistons and cylinders
- Install the head and check the squish
- Install new reeds and the intake boots
- Pressure test.

And if it passes, drop it into the bike.


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PostPosted: Thu Mar 02, 2017 8:06 pm 
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Good work Steve, lots of progress there :)

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PostPosted: Thu Mar 02, 2017 8:15 pm 
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Off Road wrote:
According to the parts fiche at Boats.net, the RZ350 and the Banshee use the same fiber clutch plates.
However, EBC lists different clutch kits for the RZ and Banshee.
EBC CK2240 - RZ350
EBC CK2279 - Banshee

I happened to have both clutch kits at the shop, so I opened them up to have a look.
It turns out that the Banshee fibers have more surface area than the RZ, so I'm going to use the Banshee clutch in the new engine.



The Banshee probably never came with the rubber rings that the RZ had in the clutch. The EBC # for the Banshee might be the same as their number for the FZR1000.


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PostPosted: Fri Mar 03, 2017 2:40 am 
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Steve, you're gonna have this thing running before I get back from California.

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PostPosted: Mon Apr 03, 2017 2:03 pm 
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I got the cylinders and head installed.
Next thing on the list was to pressure test it before final assembly.

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I had a shrader valve and a couple of low pressure gauges hanging out in the garage, but I didn't know if either of the gauges actually worked.
I finally found a place that sold expandable rubber plugs so that I could seal the exhaust.
Then I bought a couple of brass fittings and a couple of pieces of aluminum bar.
I hooked up both the gauges just to see if they were functional.
Both gauges worked, but there was a 2 psi difference in the readings.
The small black gauge read 5 psi, while the larger gauge read 7 psi.
That averaged out to 6 psi, and the engine held that pressure for over 6 minutes. :smt038

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Since it passed the pressure test, I finished putting the new engine together, and pulled the old engine out of the bike.

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While the engine's out of the frame, I figured I should clean some of the scum off the bike.
As far as I know, the last time this bike was actually clean, was 4 years ago, when I first put it on the road.
After I finish with the rear end of the bike, I'll move on to the front end.

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Last edited by Off Road on Tue May 09, 2017 11:02 pm, edited 1 time in total.

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PostPosted: Mon Apr 03, 2017 7:11 pm 
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We need a "like" button. I'd be hitting it all the time on your threads. Outstanding work, love the pics. How'd the Banshee disks fit? Thinking of that as an future option.


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PostPosted: Tue Apr 04, 2017 4:20 am 
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You dont have a "Like Button"

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Dave

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http://www.dlra.org.au/index.htm


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PostPosted: Sun Apr 09, 2017 1:59 am 
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No pics available on my iPad. Boohoo!

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PostPosted: Mon Apr 10, 2017 1:48 am 
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hondaror wrote:
No pics available on my iPad. Boohoo!


Me TOO, :smt013

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PostPosted: Mon Apr 10, 2017 1:50 am 
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no pics on laptop either... either the hosting site is down or theyre gone?

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Like Watches? You will love www.PloProf.com & www.DeskDivers.com


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PostPosted: Wed May 10, 2017 1:10 am 
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Disco wrote:
We need a "like" button. I'd be hitting it all the time on your threads. Outstanding work, love the pics. How'd the Banshee disks fit? Thinking of that as an future option.

Hey Disco, thanks for the kind words.
Banshee clutch discs fit just fine. Don't know how they work , as I haven't got the motor running yet.


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PostPosted: Wed May 10, 2017 1:11 am 
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Last time I posted, I had just finished disassembling the rear end of the bike.
So, I've cleaned all the grease & chain lube off of the frame, shock and swing-arm, then I went over the aluminum parts with a bit of polish.
They cleaned up pretty good.

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They're definitely not show quality, but they do have a bit more shine than they did.
(Right signal has been polished, the Left signal was not.)

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A while back I mentioned that I got some new Metzeler tires, becuse the old Bridgstones were getting a little flat in the middle.
The flat spot was a bit hard to see in my previous pictures, but it's pretty obvious in this one.

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When I put the rear end back together, I also installed a new set of FZ600 dogbones.
The new dogbones are 9mm shorter than stock, and will raise the rear ride height by 30mm.
I also installed the exhaust hanger for the new pipes. It's mounted behind the footpeg bracket, using the footpeg bracket bolts.

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Anyway, once I polished the swing-arm and rear turn signals, I kinda had to polish the front turn signals.
And then I polished the clip-ons, and the top triple tree.
The bike was starting to look a bit better, so I figured I might as well do the headlight bracket.
However, the headlight bracket is a complicated piece, with lots of corners and angles and small little spaces.
So in order to do it right, the bracket had to come off the bike.

But, the brake line runs through the middle of the bracket, and in order to get the brake line free, I had to remove the gauges.
However, in order to remove the gauges, I had to remove the top triple tree.
And before I could remove the triple, I had to take off the clip-on bars.
But there was not enough slack in the brake line to lift the clip ons up aff the forks tubes.

So, I took off the brake calipers, removed the front wheel, took off the front fender, dropped the forks, took off the clip-ons,
removed the top triple, took off the gauges, and then headlight bracket just about fell off the bike.

At this time, there was only the steering stem nut holding the lowere tripple in place, so I figured I might as remove it and regrease the front end.

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I gave the headlight bracket a quick polish, and it shined up a bit.

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Then the front end was re-assembled.

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So, the bike's all cleaned, polished and re-greased. The engine's rebuilt and assembled.
The only thing left to do is a bit af re-assembly.


Last edited by Off Road on Wed May 10, 2017 1:15 am, edited 1 time in total.

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PostPosted: Wed May 10, 2017 1:11 am 
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Some of you people like stories, and and some of you like stories with pictures.
Funny, so does my 4 year old nephew. Just saying. :smt003

Here's a couple that you might like.

In early April a fellow approached my friend and said he had a Mint set of Toomey pipes for sale.
He said the pipes were perfect. No dents. No scatches. Polished Aluminum cans. New Toomey decals.
According to the seller, they were Perfect.
My friend said he was interrested in buying them and asked how much money they were.

The seller said that he paid a lot of money for them, but he would be willing to sell them for $50.00 less than what he paid.
My Friend said that he'd pay the extra $50.00, and give the seller the same amount that he bought them for.
So my friend reached into his pocket and handed the seller a big stack of cash, and asked the seller to deliver them to his shop.

My friend keeps running into the seller and every time that he does, he asks if the guy brought the pipes.
The seller always says "No, I forgot to bring them in".

Well, this has been going on for about 6 weeks now.
My friend paid top dollar in advance, and every time he asks about the pipes, the seller says that he'll bring them in Soon, or he'll bring them in later in the Week.


Now I know what you're probably thinking, but I swear, I'll dig out the pipes and give them to Rory real soon, maybe later this week. :smt005


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PostPosted: Wed May 10, 2017 1:12 am 
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Stroker motors, and big bore kits. Lots of people looking to get more HP out of there engine.
If your thinking of doing this, there are a few things that you should know.

High performance motors require a bit more care and maintenace.
And you might find that there comes a time when you have to take the motor apart in order to do some minor adjustments.
If you do have to do some disassembly, there are a few things that you should learn to recognise.

The first thing you should do is check for damage to the head.

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Then you should check the piston. In this motor, one of the pistons was slightly overheated.

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Here's some more piston parts, a top end bearing, parts of a ring, and the top part of the rod.

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Make sure that you inspect the cylinders, looking for damage to the steel liner, or maybe even some cracks in the aluminum.

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And don't forget to check the inside of the pipe.
That's were we found the wrist pin, along with the rest of the piston and top end bearing.

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PostPosted: Wed May 10, 2017 2:40 am 
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Wow. yes thats not going to polish out... :/

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Yamaha '85 RZ350 F1 & '83 RZ & RD Athena 421 LC & XT500 Supermoto & Honda MT250... See them all on www.2smoked.com

Like Watches? You will love www.PloProf.com & www.DeskDivers.com


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