Olivier PATROUIX
2023-06-23
I've purchased from a breaker a Yamaha TZR 250 in order to get some spares for my wife TZR 250 (2ma French specifications).
But after a carb. cleaning, the bike fires perfectly so I change my mind and this bike will be a track day bike.
Part one Track bike for 2005 (stock bike)
Part two Track bike for 2006 (TZ250 seat)
Part three Track bike for 2006 (TZ250 fairing)
Part four Track bike for 2006 (TZ250 fairing, dashboard)
Part five Track bike for 2006 (Track ready / Picture on track)
Part six Track bike for 2007 (Larger radiator / Picture on track)
Part seven 2008-06-15 (Fork and oil tank setup)
Part eight 2009-08-02
Part nine 2010-07-04
Part ten 2011-06-28 (Engine rebuild / Track at Magny Cours)
Part eleven 2011-10-18 (Riding at Pau track the 16th of October 2011)
Part twelve 2012-06-23 for 2012
Part thirteen 2012-08-14 for MC 2012 !!!
Part fourteen 2012-09-17 for 2013 (Riding at Pau track the 17th of September 2012)
Part fifteen 2013-04-08 for 2013
Part sixteen 2013-09-15 for 2013 (front end)
Part seventeen 2014-06-14 for 2014 (TZR50 fuel tank and paint job...)
Part eighteen 2015-06-23 for 2015 track days
Part nineteen 2023-06-23 for 2023 Road
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TZR 250 1988 2XT (not 2ma or 1kt) Nikasil cylinder with extra exhaust port |
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Bigger reed block (8 petals) larger rims |
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Paint scheme and evolution (in Japanese) |
I've checked on the bike details that show the differences between European and Japanese model.
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The bike arrives at home and some parts are missing : filling cap, petcock, screen and hand blisters. For sure tires are old and dry... |
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Japanese sticker for cable routing, YSP sticker for Yamaha Sport Plaza |
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The left cylinder is marked 2XT not 1KT or 2MA. So it is a late TZR parallel twin, the last version before the reverse one. The clock is showing 2844 Km. Don't know if it is accurate? |
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Front rim size : Left image 2xt : 2.75" x 17" (rear 3.5" x 17") Right image 2ma : 2.15" x17" (rear 2.5" x 17") |
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Front Axle size : Left image 2xt : 15mm Right image 2ma : 12mm |
For our 2005 RD500LC club track day event as my RD500LC is not currently running, I've decided to prepare the TZR for the 2 strokes meeting on the Lurcy track. I've taken the rear wheel of my wife's bike, put new rubber on her bike front wheel and I'll use the front rubber on my TZR. Looking in my spares, I've found a screen which needs cleaning and polishing... Finally, I was ready for the meeting.
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Rear view of the 2 TZR, the 2ma rear wheel has been changed to a TZR125 1994 wheel (same as the 2xt). Japanese rear light cluster. |
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Clocks Left image 2xt : over 80km/h red light Right image 2ma |
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On the 2ma, the top mounting point breaks so I take the 2xt shock and get from the UK a R1-Z unit with remote reservoir. |
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The original tank is rusty, the filling cap and the petcock were missing so I manage to get a complete tank from ebay again. First track session in 2005 at the RD500LC Club meeting at Lurcy |
The 2006 club event is the 1st and 2d of July. I'm working on the next stage of my "race" bike. I would like to keep the bodywork as spare for the road TZR so I start fitting after-market race fairing and seat to the bike.
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On the left Mark TZR350 (RZ engine) with a TZ250 bodywork. On the right, the TZ250 1991-92 being adjusted to fit. |
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Other views |
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A TZ250 1993-94 bodywork being purchased from ebay with a 2000 seat and front mudguard. The seat will be used on my FZR400RR-RD500LC project bike. |
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Brackets and mounting have been made to relocate CDI, remote reservoir, voltage regulator and rear brake reservoir |
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Other views. |
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Jolly Moto pipes cleaned |
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Jolly Moto pipes on the bike. |
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I'm not sure if it will be OK for 2006 event but I'd like to do the YZR500 OWC1 paint job. |
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First test with the TZ250 fairing |
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Upper fairing bracket and side mounting done. |
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Fairing is currently at ASE for filling... and seat is now in primer. | |
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Number plates are painted in flashy yellow. |
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Marking the number plates |
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White paint applied, not perfect but it will do for track day meeting. |
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To be perfect it needs a water sanding with 1000 grade. |
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Then a clear-coated paint. | |
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The upper fairing is now in primer With flashy yellow number plate |
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Lower fairing painted in black. |
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Other side of the lower fairing | |
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Fairing bracket and upper fairing bracket painted in gloss black |
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Seat bracket and instrument panel running bike. |
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Seat on the bike with fuel tank. |
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Lower fairing with black paint masked |
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Plate number masked and red paint on |
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Other view | |
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Red parts are ready to be masked (need more drying) |
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Red parts masked, upper fairing ready to be painted in white. |
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White paint on |
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White on masked |
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Seat pad in neoprene foam |
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Bike is painted but no clear-coat !!
Date 29 June meeting 1 & 2 of July so no more time.
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Bike assembled |
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Bike at RD500LC club meeting. |
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On track picture by JPM |
Work for 2007 track session.
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TZR125 Belgarda radiator, bigger, curved will help to keep the engine cooler |
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First test for the radiator. |
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Front view |
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Mounting |
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TZR250 2XT reeds bigger than 2MA |
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On track at Lurcy 2007 JPM photo |
Work for 2008 track session
Work for 2009 track session
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Right fork seal is leaking. So it has been changed and new dust seals also. Next step will be new fork tubes because these are rusty. |
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Starting the bike after 700km on a trailer !!! |
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Track picture and front tire after the weekend. |
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Rear tire after the weekend. No problem all weekend. |
Work for 2010 track session
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Old and new fairing mounting |
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With choke lever |
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With fairing. |
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Damage to be repaired. Common problem from bike of this age. |
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Metal sheet is too thin that welding is not possible. I've cut the tank and weld a new piece of metal. |
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Need to buy oxygen to finish the welding. Welding done and started paint stripping |
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Paint stripping. |
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More stripping and ding to be repaired |
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Other side and welded zone |
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Just bought pistons from Japan and not available anymore from Yamaha !!! even in Japan. link to pictures |
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"Racing" dashboard Digital temperature and shift light |
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Painted tank on the bike |
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Painted tank on the bike and YAMAHA sticker too big !!! |
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"Racing" dashboard in the fairing. | |
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Sticker on tank |
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Bike ready for next weekend : track day at Magny Cours |
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The tank was sealing well but the tap was leaking so I've used fuel couplers... The engine went pop by the end of Saturday session |
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Track pictures from JP Marin |
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Engine rebuild due to break down during last track session. |
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Striping it down. |
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Engine out of the frame. |
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Engine on the desk. |
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Head OK no carbon no marks. Right piston nice top no mark in cylinder. |
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Left piston nice top but marks in cylinder. Look like a bearing as gone : big end or crank... |
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Cylinder with marks !!! |
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Cleaned engine and 2XT read intake. |
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Engine on the desk ready for pouring gear box oil. |
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Used spare crank |
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Cleaned head and right dome. |
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Left dome with marks (small ones). |
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good clean to the done (left have small park). |
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Left damaged cylinder. |
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Left damaged cylinder & right cylinder (on the right). |
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Right undamaged cylinder. |
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2XT pistons : right OK / Left KO. |
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2XT read valves : 8 petals. |
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Clutch and clutch case. |
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Damaged big end bearing with copper pieces from the conrod !!! |
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Metal pieces !!! Red circle = metal pieces. |
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Metal pieces !!! |
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Metal pieces again !!! | |
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One half of the crank is gone. |
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Big end gone close up. Spare crank need an overhaul too. |
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Crank case with big end marks. |
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TZR 2XT intake with room for tuning !!!!. |
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While waiting for the price of crank rebuild, I've cleaned the edge of the crank case on the intake. |
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I've cleaned the edge and rounded the corners. |
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Here are other views. Don't know if I need to do further. |
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Here are picture of 2XT tuning by ToshTec in Japan (Assy Blog 1 & 2 & 3). |
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Checking how the intake, cylinder and case match !!! |
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Some small zones where improvements can be done !!! |
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Other views but not sure this time and effort will lead to noticeable improvement. |
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I've seen that the exhaust diameter could by enlarge to suit JollyMoto diameter. | |
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Crank ready to be shipped to RoadAndDirt Performance Bike Part in the UK | |
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Piston arrive from Japan (Thanks Nao). Small custom cost but OK Need to buy piston pin and clip |
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Measurements : 56.35mm Play : 0.05mm |
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Here are the picture from RoadAndDirt !!! Webs have to be changed As he is a good dealer then he offers me a discount. Super dealer. |
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Spacer for cutting the reed paper seal. CAD file -> CNC Cutting |
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A good basis for cutting the paper seal not included in the 1KT or 2MA gasket kits. |
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Yamaha parts for the top end rebuild | |
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JollyMoto pipes o'ring rebuild. |
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JollyMoto pipes oring rebuild. Unrusted & ready to be painted. |
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JollyMoto been painted. |
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Close view. |
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Not bad for 15years old pipes. |
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Clutch cover cleaned. Oil filter too. |
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Crank rebuild Piston kits |
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Yamaha crank seals |
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Crank cases closed Pistons on the conrod |
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Cylinders on |
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Head gasket with Loctite 3020 |
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Head in place Engine in the frame |
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Radiator and JollyMoto pipes |
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Missing intake manifolds |
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Fuel tap testing : volume : 0.6 l Gravity flow with 25cm fuel line : fuel line only : 22s -> 1.7 l/min -> 102 l/h quick coupler 6mm : 52s -> 0.69 l/min-> 41.4 l/h fuel tap : 49s -> 0.73 l/min -> 43.8 l/h Do you think 41 l/h is OK for the 250 ? |
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Dismantled fuel tap Not lot of space for enlargement. |
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The bike has run on the 2 cylinders. Fuel circuit on the bike. Heat cycles done => ready for track day. |
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RD500LC French Club meeting done without any problems : nor on the engine or the fuel system |
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Thanks to RoadAndDirt for the crank service (Hi Dave) Bike with ILoveMotor stickers on. |
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Track pictures by JP Marin |
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Old fairing bracket broken during Magny Cours session. |
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New bracket in progress made in stainless steel. |
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Welding and tachometer mount to be added. |
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Here is the bracket. Welding is not perfect but I hope this will be OK. |
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Other views. |
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Mounted. |
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New tyres ordered Heidenau K66 - front in 100/80 compound CUP - rear in 130/70 compound std. |
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Maybe more a all season tire but it is a test and will be OK for winter track session!!! |
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Fitted by Meca Moto Service in Anglet. |
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Nice thread. |
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Read for Autumn track days !!!! |
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Pitted fork on my 2XT so tube will be changed. Here donor front end (2MA one) |
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Close views. |
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Dismantling : - It was time to do !!! - tube is OK. |
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Dismantling : - Oil damper problem!!! - second leg OK |
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Dismantling : - tube is OK |
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Dismantling TZR 2XT: - fairing - pitted leg |
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Dismantling TZR 2XT: - pitted leg - leaking seal - cracked dust seals!!!! |
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Dismantling TZR 2XT: - no front end bike!!!! - Left leg dismantled |
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Differences 2XT / 2MA (don't know if stock setup) - 2XT left / 2MA right - spacer (hole in 2MA) - damper rod (bottom) - 2 holes 6.9mm on 2XT - 1 hole 7.9mm on 2MA |
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Differences 2XT / 2MA - 2XT left / 2MA right - damper rod (bottom) - 2 holes 6.9mm on 2XT - 1 hole 7.9mm on 2MA |
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Differences 2XT / 2MA - 2XT left / 2MA right - damper rod (top) - 1 holes 2.5mm on 2XT - 1 hole 1.5mm on 2MA |
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Differences 2XT / 2MA - 2XT left / 2MA right - spring : - 427mm on 2XT - 421mm on 2MA |
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Rebuild on a wooden bench ;-) : - 2MA damper rods - 2XT springs - new seals |
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- 2MA dust seals - oil SAE15W Forks done no oil. |
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BlueOil fork oil - 450cc per leg Front end back on the bike |
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Upper fairing on the bike Next a warming up... |
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Here some pictures of the bike ready to go on the trailer |
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Some new stickers |
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Jimmy's paddock hospitality and van |
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Bike on the rear stand. My friend trying to follow Jimmy!!! |
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Some morning pictures |
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After session debriefing... Lot to say on trajectories |
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Re-fueling for afternoon sessions 4 strokes bikes !!!! |
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Track facilities |
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More pictures |
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End of the day... what a day. Many thanks to Jimmy. |
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The K66 front after the track day. Left turn side. |
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The K66 front after the track day. Right turn side. Worst then the left -> more right turns !!! |
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The K66 rear after the track day. It seems better than the front !!! |
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Some ideas for 2012 - the fork - the front wheel - the front brake(s) |
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Could be a mix of FZR400R fork and braking system with TZR125 4FL wheel ? |
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Found some plugs for the pipes... to prevent moisture to come in !!! |
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My RD500-FZR400 track bike and the second hand FZR400 fork just bought. |
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Lower yoke well rusted but after a little work. |
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Upper yoke with a broken ignition switch bolt. A tack weldding and voila !!!! |
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Upper yoke after a quick clean. |
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fork legs : seals and dust seal need to be replaced. Complete fork after the little cleaning. |
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Lower T comparison Strangely the bear seats are wider on the TZR250 stem. Decision : stem axle swap |
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Axle comparison : - FZR400 on the left - TZR125 on the right 125 axle can't be adapted... |
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TZR wheel in FZR400. |
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TZR wheel in FZR400. Twin disk setup... |
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Second hand axle before and after cleaning. |
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TZR125 wheel in the FZR400R fork legs. Waiting for the lower yoke to be modified. |
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Removing the speedo drive. |
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Replacement by an anodized alloy part (turned one). |
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TZR125 wheel in the FZR400R fork legs without speedo drive. |
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TZR125 wheel in the FZR400R fork legs with the FZR front mud-guard. |
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I've got my FZR400 calipers and braided hoses (Philou ;-) ) Now 2 FZR400 disks.. |
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Front Wheel Stand |
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Video | Front Wheel on the stand. Video too |
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Thermo forming for making mold |
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Many thanks Philou for these TDM rotors .... |
Work for MC 2012
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Camera Mounting looking rear Prototype |
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Camera Mounting looking front Alloy part |
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Camera Mounting looking rear And final mounting on the rear. |
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Camera Mounting looking front And final mounting on the front. |
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Camera Mounting looking front/rear |
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On-board views front & rear Video to come |
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Cleaned LH foot-peg Greased and adjusted |
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Cleaned RH peg | |
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HT painted pipes Left & Right |
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Seat Front quick fasteners |
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Seat Rear quick fastener |
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FOX RACING TALDEA Identification |
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FOX Racing Taldea private testing !!! |
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Alloy grid on lower fairing |
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Alloy grid on lower fairing on the bike |
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Alloy grid on lower fairing on the bike | |
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Bike ready for RD500LC Club meeting by the end of June 2012... |
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See : MC 2012 |
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FZR400R Fork adaptation Grinding welding and pressing axle out |
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Job done on TZR T |
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TZR axle ready to weld on FZR T |
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Cleaned and ready for primer |
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In primer |
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In metallic silver (Vito Van paint) |
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Dried. |
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With clear varnish on. |
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With top triple T. On fork. |
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Upper T sanded and stock clip-ons. | |
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Upper T painted in silver |
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Upper T painted in clear varnish |
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Left hand (throttle) slightly bent. Un-bent in the vice so a little mark but will not seen after with grip. |
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The result and painted in primer. |
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Left hand in primer. |
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Right hand in primer. |
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YamBits fuel line kits for the carb. http://yambits.co.uk/ |
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New 8mm fuel coupler to replace 6mm one !!! | |
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Carburetor cleaning. |
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Carburetor cleaning. Is this air-jet common on 1KT/2MA or specific to 2XT (Maybe FIII mod). Float height is 17.50mm. |
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Carburetor cleaning. Plastic fuel filter gets crap!!! |
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Carburetor cleaning. Power-jet dismantled. |
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Carburetor cleaning. Carb bowl ready to reassemble. Carbs done. |
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Cleaned air filter and oily again. |
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Carburetor cleaning. News vent and overflow hoses... |
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Carburetor cleaning. Float set to 16mm and new fuel hoses... |
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Fuel line 8mm the tank. |
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Fuel filter on line 6mm. Quick coupler as petcock. |
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Carb. back on the bike. |
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Airbox back too and bike running. |
Pau track day
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Ready for the trailer. |
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Dashboard control.. |
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Nice day at Pau.. |
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Single exhaust TZR !!! Martin77 pipes on soon. |
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Paddock tour mostly diesels!!! |
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Nice single using KR1 frame with Aprilia engine. |
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RAK =>Rotax Aprilia Kawasaki. | |
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At the end some 2 strokers with KR1. |
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Adaptation fork FZR400R R6 fork cap. |
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Comparison R6 FZR400R | |
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R6 cap on the fork |
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TZR steering bearings FZR fork seals and dust seals |
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TZR fork off |
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TZR fork off Lower bearing on the TZR-FZR lower T |
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Top steering bearing on the frame Lower T on the frame |
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Upper T on the bike Draft fork fitment on the bike |
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Draft fork fitment on the bike Upper fairing on |
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View from rider seat With clip-on on |
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With clip-on in primer Standard FZR400R front end |
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Standard FZR400R front end |
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Bike in horizontal position Wheelbase : 1374mm SwingArm axle height : 382mm Attention : garage ground in not fine. |
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Fork T height : 920mm Attention : garage ground in not fine |
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Bike in horizontal position 10mm offset difference |
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Upper fairing on |
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Upper fairing on. XJR1300 and R6 fork caps. |
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In the center, the FZR400R standard setup without any tuning setup. |
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From left to right, XJR, FZR400 and R6. XJR fork cap installed. |
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Installed and tuned for the FZR400 to be adjusted for the TZR250. |
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Android Bubble level application to setup the chassis !!! Swing arm angle 11.3° / 11.2° |
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Android Bubble level 1° error ? To be calibrated more accurately |
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Front castor angle 90°-62° = 28°. Should be near to 26°. To be calibrated more accurately |
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Double dogbones cut in PVC sheet for testing (CNC). 2 positions 107mm & 102mm (original 112mm) |
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Double dogbones cut in PVC sheet for testing. |
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Double dogbones on the bike at larger position : 107mm between holes |
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Front fork castor : 68-69° (angle application not calibrated) | |
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Double dogbones on the bike at smaller position : 102mm between holes |
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Front fork castor : 67-68° (angle application not calibrated) | |
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Made 103mm dogbone to be able to :
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Made some plastic spacers for the handle bars. |
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Bubble level to calibrate the mobile phone application. |
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Horizontal measurements is 1-2° but to be added or subtracted . |
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Measurements on the bike (wheels on the ground) :
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Bike vertical Balance :
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Fork fully extended
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Hel Brake lines - front & rear for FZR400R |
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Hel Brake lines - on master cylinder - left hand caliper |
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Hel Brake lines - right hand caliper Ready for new brake fluid |
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New DOT 4 fluid back in Maser cylinder where it should be !!! |
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Right & Left caliper on fork legs with pads in. |
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Front looks like a bike again. Thanks Peio |
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Clip-on silver painted and clear coated. Also fairing bracket from black to silver. |
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Fairing back on... better view. | |
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Fork dismantled |
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PVC tube heated to make a seal tooling. Lower leg ready for primer. |
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Lower leg in primer |
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Lower leg ready for metal silver paint. |
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Fork legs painted and ready for clear coating. |
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Lower leg ready for primer and in clear coated. |
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Lower leg in clear coated |
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Lower leg ready for rebuilding. |
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FZR400RR 3TJ 43mm Fork Tubes Fork Spring Free Length - 346mm Minimum - 341mm Spring Rate - 6.5N/mm (0.65Kg/mm) Fork Travel - 120mm |
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Home made tool for locking the plunger |
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Fork on the tooling ;-) Fitting the slider and spacer |
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Fitting the seal. Fork legs back in one piece. |
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Nice rebuild forks. Oil Capacity - 509cm3 (17.9Imp Oz) 80mm From the top of inner tube, fully compressed without spring. 10w Oil (I used 15w for a stiffer ride) |
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Fork on the bike again ;-) |
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Front tire ordered to replace the old BT45 Heidenau K66 in 110/70x17 on the way. Arrived 23/05/2013 (with Yamaha Chappy set ;-) ) |
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Thermo forming for making mold Thanks Denis ;-) |
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Little sun shine so outside pictures : front views. |
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Little sun shine so outside pictures : front views. |
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Mold and first trial of carbon kevlar front mudguard. Thermo forming for making mold |
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Far from perfect but will see ;-). Thanks Francis ;-) |
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Out of the mold. Quick deburring and fit on the fork |
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Fit on the fork. Not that bad for my first part ;-) |
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Ready to be fitted... |
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And voila !!! Thanks Flop ;-) |
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Front end ready |
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The upper fairing on. |
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Almost good. 01-06-2013 |
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Double dogbones made in 4mm steel and laser cut... Thanks Georgy ;-) |
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DogBone on the bike and hop now ready for nickel plating. Plating done thanks Peio ;-) |
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TZR 50 fuel tank project Manage to buy a NOS TZR50 tank |
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Will do the same modification as my friend Peio http://rd500lc.free.fr/forum/TZR50-Tank/ |
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FZR400 fuel outlet GIMP picture to check paint scheme |
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Tank in the sun shine !! | |
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Tank on the bike. |
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Much narrow than the original one. Seat back on to check. |
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3/4 rear view. | |
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Fuel tank bracket modification. Welding grinding. |
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Widening tuning. |
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Ready for the new welding |
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Plates welded on. |
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Ungreasing / phosphating before painting. |
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Ready for painting. |
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Ready for painting. |
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In primer. Painted in Vito Metal gray |
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Painted in Vito Metal gray |
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Clear coated... |
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Front bracket installed on the frame... |
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Front mounting on the tank. |
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Rear mounting on the tank. |
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Fuel tank on the bike. To be adjusted or redesigned with the front fitted ;-) |
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Test with FZR400RR seat but will not go. Tank fitted in the front. |
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Rear mounting to be made again as expected... FZR petcock fits perfect |
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New mounting setup |
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Side view CNC PVC rear bracket |
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Mounting bracket |
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Mounting bracket |
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Tank back on the bike Good line up |
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With the seat on. Paint sanded |
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Paint sanded |
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Lower Fairing sanded |
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Upper Fairing sanded |
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Fairing and seat in primer |
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Fairing and seat in primer but sanded |
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Fairing with the white zone masked |
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Seat painted but no clear coat |
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Fairing painted but no clear coat |
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Carb cleaning with ultrasonic machine |
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One looks almost new |
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One still not as good as new but machine can do more. |
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Yamaha seat valve kit for RZ350 ref : 48H-14107-28 Same as TZR250. |
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Aftermarket carb rebuilt kit Will do a little review. |
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Rear wheel painted in mat black. Quickly done but OK |
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Fairing and seat on the bike |
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Lower fairing on. |
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Stickers on the seat |
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Stickers on the seat |
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Stickers on the fairing |
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Stickers on the fairing Logo TZR250 |
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Stickers on left lower fairing Logo Yamaha |
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Stickers on the right lower fairing |
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Stickers on the nose cone |
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Look racing of the garage Now clear coated |
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Right side |
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Left side |
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Fuel level checked. Looks OK. |
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4 petals 2XT reed valves. Intake boots |
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Carb back on the bike. Airbox on. |
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Clear oil line kits from YamBits. Rebuild started. |
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Clear oil line kits from YamBits. Blue oil coming from the pump. |
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Try a nose cone line? |
Work in 2015
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Carburettor cleaning with ultrasonic machine Not dirty but better to start trackday session. |
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Better loking ones. |
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Carb back on the bike. Started like a charm !!! |
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Temperature unit New cheap digital gauge |
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Dashboard form style |
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Sender on the head. Some electronics noise. |
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No more noise. |
Work in 2023
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Back to road version. |
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To be continued |
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!!! |
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!!! |
