The tarting up of Dandi

[gijoe1313]

Righto, time to start a most excellent thread about restoring a classic RZ205R/RD250R to running order. This will not be a road bike, but a dedicated offering to the Gods of Speed.

Dandi will be tarted up with bling and trick bits that her orginal designers wouldn't have thought of. Firstly, we have to take her right back to bare frame and all componentry taken off, examined and thrown away. :yes:

After giving her a grand drive back from the Tauranga region, Donor, Insane1 and I promptly gave her a good spanking, it was three on one action and then the porn action really got going when Donor got Zeozen into it!

Zeozen was a good fluffer and did dodgy work with tools and ended up bleeding (a worthy sacrifice!)

Insane1 did an excellent job removing the tank (sounds of rust inside) and removing various bits.

The serious business got to removing the engine block and getting the head off to see how bad it was. Credit goes to Zeozen, even being a noobie to the zen of motorcycle maintenance (and general tool use!) he spotted a problem, but we dismissed him out of hand. Just goes to show that a Padawan can still give the master the learn! :lol:

Seriously bad. The plonkers who stuffed it in the container didn't remove the fluids. We snipped off all the cables (shagged and rooted they were) and will probably rewire the entire master loom.

We broke bits, we hammered things, we got filthy and mucky playing with Dandi's precious bits, crude and rude allusions of a sexual nature would have gotten the PC brigade frothing and pulling at their armpit hairs! :innocent:

Already thinking of Brembos, Ohlin shock, cone air filters, steering dampener, replace clip ons with single stock bar, etc. Ideas flowed thick and fast with the banter we had.

Okay, that's enough guff. Need pictures. Insane1 and Donor took ample so will bend their arms to get them to me.

This is an open project bike for KBers, especially people new to biking that want to learn more about the pleasure and pain of working on bikes. From the ground up.

Anyone who wields a tool or waves a general helping hand in our direction will be entitled to ride Dandi when she's done and dusted! :msn-wink:

So c'mon down to the South Auckland KB does Dandi Spanner Nights being advertised! :yes: This will be also part of a working bee on Donor's Man-shed for Bikers, where we will make it a shrine to the Biking Gods and Speed.

[yungatart]

Oi you!!! I had nothing to do with any of this!!!!

[gijoe1313]

Oi you!!! I had nothing to do with any of this!!!!

That's not what you said last night! :msn-wink: :devil2: And I can neither confirm nor deny anything that may have been done or said.

And for that matter, anything else! :innocent:

[crashe]

Ok I can bring the sledgehammer to help you out, to bash things off. (pt)




So what other tools do you think you might need...?

[McJim]

I can't be arsed with prose - where are the pictures ya bastige?

[Squiggles]

ill help if needed, have a few odd tools that've come in handy when i've been working on the bikes

[gijoe1313]

Okay, finally managed to get some headway on Dandi! The crew turned up tonight...

Donor
Bass
Xerxesdaphat
Big Dave

Did some work on stripping all the parts off Dandi's frame and put all the gubbins into various boxes (Bass/Big Dave both made the comment that we would end up with parts leftover when we re-assembled her!)

The usual power tools being used to grind off bits, xerxes bending a drill bit and massaging a hole into his hands with various tools and Donor doing a bender and saying things like "I want to hit it hard with something big" :o ooer!

Will get frame sandblasted back to bare metal and powder-coated in a suitable gijoe type colour :innocent:

And if you missed the piccies from the other thread... http://www.kiwibiker.co.nz/forums/showthread.php?p=1123351#post1123351 ... otherwise deja vu will now be setting in at this point... :eek5:

[gijoe1313]

As mentioned on the other thread, I went out today and looked for some of those shelving benches Big Dave mentioned. Warehouse sold out and there were some naff looking ones.

Went to Mitre 10 Southgate and found the ones for $79.82 or something ludricous like that, bought them, assembled them - bunged all the bits of Dandi into some tote trays I have (sorted according to function) and ziplock bags for little bolts, gubbins and stuff.

Looks rather nice, will probably buy another set of those shelves so we don't have to do it asian style and squat on the floor to do it!

The amazing thing is I have an entire service manual for the RZ/RDs! :woohoo:, including the supplementary one - I've got all the parts files and numbers of them too! Amazing. Doesn't sound like any job I've done!

[Donor]

Well, after an hour of towel and plywood jamming, the primary drive nut thingy wasn't going to bloody budge, so bunged the bottom end of the donk into the boot of my cage-o-cartage and brought it home.

Shot up to my brothers workshop this afternoon, and 3 seconds with an impact gun, the bloody thing is off, so we're almost ready to complete the strip down and send the block away to have nasty and nefarious things done to it! (Like, have all the corrosion from god knows how many months/years of water sitting in the seriously hydrolocked cylinders!)

I've sacrificed a days riding tomorrow to finish off home chores, so will hopefully be bending the upper limb of Mr Joe into perhaps organising another spanner night next week.

*GLEE*

[Big Dave]

Good work - I was going to use the term Chinese laundry - but I knew it wouldn't wash.



(last one - and you started it)

[xwhatsit]

Well, after an hour of towel and plywood jamming, the primary drive nut thingy wasn't going to bloody budge, so bunged the bottom end of the donk into the boot of my cage-o-cartage and brought it home.

Shot up to my brothers workshop this afternoon, and 3 seconds with an impact gun, the bloody thing is off, so we're almost ready to complete the strip down and send the block away to have nasty and nefarious things done to it! (Like, have all the corrosion from god knows how many months/years of water sitting in the seriously hydrolocked cylinders!)

I've sacrificed a days riding tomorrow to finish off home chores, so will hopefully be bending the upper limb of Mr Joe into perhaps organising another spanner night next week.

*GLEE*

<hints id="hah_hints"></hints>Idiot! I thought we'd agreed to have a go with the grinder next spanner night! How the hell are we going to have any fun now?

:innocent:

So that's why we were pulling it apart. Two-stroke bottom ends are actually more complicated than the four-stroke variety, although looking at that flat chunk of aluminium you had the audacity to call a `cylinder head' I can see where they make it up in the simple stakes.

[gijoe1313]

<hints id="hah_hints"></hints>Idiot! I thought we'd agreed to have a go with the grinder next spanner night! How the hell are we going to have any fun now?

:innocent:

So that's why we were pulling it apart. Two-stroke bottom ends are actually more complicated than the four-stroke variety, although looking at that flat chunk of aluminium you had the audacity to call a `cylinder head' I can see where they make it up in the simple stakes.

Of course you know it's twice as complicated as yours! :innocent: However, what a lot of Bass said, I could only comprehend half of it, the other half I still didn't have a clue (just went :yes:)

Actually we cheated again today, Donor and I spend a bit more time just now pulling off thingummies and whatchallmacallits with those gizmos and doo-hickeys. We stopped cause we knew you was posting this up as we doing so! :innocent:

A real chinese fire drill this... oops... Big Dave did say it was meant to stop... typical chinese, you start and finish... then half hour later... :innocent:

[Donor]

Donor and I spend a bit more time just now pulling off thingummies and whatchallmacallits with those gizmos and doo-hickeys.

Note big hammer and block of wood... muhahaha...

[Kickaha]

Two-stroke bottom ends are actually more complicated than the four-stroke variety

How do you work that out?

[geoffm]

Well, when you get it running, give me a call and we can do some dyno development.You really want to run it stock, before you start porting, etc so you can tell what difference you have made.
Banshee big bore kits and stroker cranks will give you some big numbers, one on the RD forum is 500cc cyls.
You can get 70hp from an RZ motor, but they are a handgrenade - essentially a TZ350 without being designed for it.
KR1 S carbs work well for the street - you can buy them new as well (Kiehen PWK28 http://www.gareth.evans9.btinternet.co.uk/350-kr1carbs.htm), for race use you might need something bigger. There is also an adjustable electronic ignition for them which apparently works well - I will see if I can find the link. The rest is porting, pipes, head and assembly. The cranks won't take over 10500rpm with the standard flywheel.
A Yam R6 shock is an upgrade:
http://www.yamaha-rd.com/forum/topic-40177.html
http://eastcoastrzs.tripod.com/id9.html
and some reading
http://domlnator.tripod.com/id11.html

[xwhatsit]

How do you work that out?

<hints id="hah_hints"></hints>The crankshaft is funny. And there's other weird things down there that I don't understand.

[Kickaha]

<hints id="hah_hints"></hints>The crankshaft is funny. And there's other weird things down there that I don't understand.

There's nothing really down there that isn't on a four stroke, as for the funny crank shaft, it's a pressed up roller bearing crank, there's quite a few on four strokes from the same era and even later, I think even your bike might have one

[xwhatsit]

I've got a roller bearing crank... I think what it is, is that system in two strokes where they compress the mixture in the bottom end before letting it into the top. And the crank is somehow involved. Or something.

[Bass]

Affirmative
+ or something

[smudge]

Interesting thread (I think) GIJOE, mostly because my RZ350 is in 5 or 6 boxes as of today. Two stroke cranks aren't complicated they just have roller bearings as they don't have oil supplied to them under pressure and you need a roller bearing to cope with that, besides as has been pointed out some 4 strokes have them too. The only other 'strange' thing is that the crankcase is sealed off from the outside world, not a complicated thing just different.

[Swoop]

How do you work that out?
Did you fail school cert mafs or summint?
The nummers are much bigger = more complex!