Track day bike project

Japanese brochure

		TZR 250 1988 2XT (not 2ma or 1kt) Nikasil cylinder with extra exhaust port
		Bigger reed block (8 petals) larger rims
		Paint scheme and evolution (in Japanese)

Model identification

		The bike arrives at home and some parts are missing : filling cap, petcock, screen and hand blisters. For sure tires are old and dry...
		Japanese sticker for cable routing, YSP sticker for Yamaha Sport Plaza
		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?
		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")
		Front Axle size : Left image 2xt : 13mm Right image 2ma : 10mm

Track day bike part one

		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.
		Clocks Left image 2xt : over 80km/h red light Right image 2ma
		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.
		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

Track day bike part two

		On the left Mark TZR350 (RZ engine) with a TZ250 bodywork. On the right, the TZ250 1991-92 being adjusted to fit.
		Other views
		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.
		Brackets and mounting have been made to relocate CDI, remote reservoir, voltage regulator and rear brake reservoir
		Other views.
		Jolly Moto pipes cleaned
		Jolly Moto pipes on the bike.
		I'm not sure if it will be OK for 2006 event but I'd like to do the YZR500 OWC1 paint job.

Track day bike part three

		First test with the TZ250 fairing
		Upper fairing bracket and side mounting done.
		Fairing is currently at ASE for filling... and seat is now in primer.
		Number plates are painted in flashy yellow.
		Marking the number plates
		White paint applied, not perfect but it will do for track day meeting.
		To be perfect it needs a water sanding with 1000 grade.
		Then a clearcoated paint.
		The upper fairing is now in primer With flashy yellow number plate
		Lower fairing painted in black.
		Other side of the lower fairing
		Fairing bracket and upper fairing bracket painted in gloss black

Track day bike part four

		Seat bracket and instrument panel running bike.
		Seat on the bike with fuel tank.
		Lower fairing with black paint masked
		Plate number masked and red paint on
		Other view
		Red parts are ready to be masked (need more drying)
		Red parts masked, upper fairing ready to be painted in white.
		White paint on
		White on masked
		Seat pad in neoprene foam

Track day bike part five

		Bike assembled
		Bike at RD500LC club meeting.
		On track picture by JPM

Track day bike part six

		TZR125 Belgarda radiator, bigger, curved will help to keep the engine cooler
		Fisrt test for the radiator.
		Front view
		Mounting
		TZR250 2XT reeds bigger than 2MA
		On track at Lurcy 2007 JPM photo

Track day bike part seven

		Fork seals are gone, now they are brand new 25/05/2008. Oil 450cc / 80mm gap / spring length 427mm. Gearbox oil is changed.
		A little oil tank is made using a over heating bottle from a Suzuki RMX50. Last year, I've almost seeze so this year an oil gauge is installed.
		The gauge is connected, tested and the SPEED  light on the tachometer is used as oil level light.
		The oil tank is full and the light is off and picture of the mounting (hole in the tap).
		The stickers are placed this make look better.
		The sponsors !!!
		The sponsors !!!

Track day bike part eight

		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.
		Starting the bike after 700km on a trailer !!!
		Track picture and front tyre after the weekend.
		Rear tyre after the weekend. No problem all weekend.

Track day bike part nine

		Old and new frairing mounting
		With choke lever
		With fairing.
		Damage to be repaired. Common problem from bike of this age.
		Metal sheet is too thin that welding is not possible. I've cut the tank and weld a new piece of metal.
		Need to buy oxygen to finish the welding. Welding done and started paint stripping
		Paint stripping.
		More stripping and ding to be repaired
		Other side and welded zone
		Just bought pistons from Japan and not avaliable anymore from Yamaha !!! even in Japan. link to pictures
		"Racing" dashboard Digital temperature and shift light
		Painted tank on the bike
		Painted tank on the bike and YAMAHA sticker too big !!!
		"Racing" dashboard in the fairing.
		Sticker on tank
		Bike ready for next weekend : track day at Magny Cours
		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
		Track pictures from JP Marin

Track day bike part ten

		Engine rebuild due to break down during last track session.
		Striping it down.
		Engine out of the frame.
		Engine on the desk.
		Head OK no carbon no marks. Right piston nice top no mark in cylinder.
		Left piston nice top but marks in cylinder. Look like a bearing as gone : big end or crank...
		Cylinder with marks !!!
		Cleaned engine and 2XT read intake.
		Engine on the desk ready for pouring gear box oil.
		Used spare crank
		Cleaned head and right dome.
		Left dome with marks (small ones).
		good clean to the done (left have small park).
		Left damaged cylinder.
		Left damaged cylinder & right cylinder (on the right).
		Right undamaged cylinder.
		2XT pistons : right OK / Left KO.
		2XT read valves : 8 petals.
		Clutch and clutch case.
		Damaged big end bearing with copper pieces from the conrod !!!
		Metal pieces !!! Red circle = metal pieces.
		Metal pieces !!!
		Metal pieces again !!!
		One half of the crank is gone.
		Big end gone close up. Spare crank need an overhaul too.
		Crank case with big end marks.
		TZR 2XT intake with room for tuning !!!!.
		While waiting for the price of cank rebuild, I've cleaned the edge of the crank case on the intake.
		I've cleaned the edge and rounded the corners.
		Here are other views. Don't know if I need to do further.
		Here are picture of 2XT tuning by ToshTec in Japan (Assy Blog 1 & 2 & 3).
		Checking how the intake, cylinder and case match !!!
		Some small zones where improvements can be done !!!
		Other views but not sure this time and effort will lead to noticeable improvement.
		I've seen that the exhaust diameter could by enlarge to suit JollyMoto diameter.
		Crank ready to be shipped to RoadAndDirt Performance Bike Part in the UK Shop Ebay Shop
		Piston arrive from Japan (Thanks Nao). Small custom cost but OK Need to buy piston pin and clip
		Measurements : 56.35mm Play : 0.05mm
		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.
		Spacer for cutting the reed paper seal. CAD file -> CNC Cutting
		A good basis for cutting the paper seal not included in the 1KT or 2MA gasket kits.
		Yamaha parts for the top end rebuild
		JollyMoto pipes o'ring rebuild.
		JollyMoto pipes oring rebuild. Unrusted & ready to be painted.
		JollyMoto been painted.
		Close view.
		Not bad for 15years old pipes.
		Clutch cover cleaned. Oil filter too.
		Crank rebuilded Piston kits
		Yamaha crank seals
		Crank cases closed Pistons on the conrod
		Cylinders on
		Head gasket with Loctite 3020
		Head in place Engine in the frame
		Radiator and JollyMoto pipes
		Missing intake manifolds
		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 clouple 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 ?
		Dismantled fuel tap Not lot of space for enlargement.
		The bike has run on the 2 cylinders. Fuel circuit on the bike. Heat cycles done => ready for track day.
		RD500LC French Club meeting done without any problems : nor on the engine or the fuel system
		Thanks to RoadAndDirt for the crank service (Hi Dave) Bike with ILoveMotor stickers on.
		Track pictures by JP Marin

Track day bike part eleven

		Old fairing bracket broken during Magny Cours session.
		New bracket in progress made in stainless steel.
		Welding and tachometer mount to be added.
		Here is the bracket. Welding is not perfect but I hope this will be OK.
		Other views.
		Mounted.
		New tyres ordered Heidenau K66  - front in 100/80 compound CUP  - rear in 130/70 compound std.
		Maybe more a all season tire but it is a test and will be OK for winter track session!!!
		Fitted by Meca Moto Service in Anglet.
		Nice thread.
		Read for Autumn track days !!!!
		Pitted fork on my 2XT so tube will be changed. Here donor front end (2MA one)
		Close views.
		Dismantling :  - It was time to do !!!  - tube is OK.
		Dismantling :  - Oil damper problem!!!  - second leg OK
		Dismantling :  - tube is OK
		Dismantling TZR 2XT:  - fairing  - pitted leg
		Dismantling TZR 2XT:  - pitted leg  - leaking seal  - cracked dust seals!!!!
		Dismantling TZR 2XT:  - no front end bike!!!!  - Left leg dismantled
		Differences  2XT / 2MA (dont 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
		Differences  2XT / 2MA  - 2XT left / 2MA right    - damper rod (bottom)       - 2 holes 6.9mm on 2XT       - 1 hole 7.9mm on 2MA
		Differences  2XT / 2MA  - 2XT left / 2MA right    - damper rod (top)       - 1 holes 2.5mm on 2XT       - 1 hole 1.5mm on 2MA
		Differences  2XT / 2MA  - 2XT left / 2MA right    - spring :       - 427mm on 2XT       - 421mm on 2MA
		Rebuild on a wooden bench ;-) :       - 2MA damper rods       - 2XT springs       - new seals
		- 2MA dust seals       - oil SAE15W Forks done no oil.
		BlueOil fork oil       - 450cc per leg Front end back on the bike
		Upper fairing on the bike Next a warming up...
		Here some pictures of the bike ready to go on the trailer
		Some new stickers
		Jimmy's padock hospitality and van
		Bike on the rear stand. My friend trying to follow Jimmy!!!
		Some morning pictures
		After session debreifing... Lot to say on trajectories
		Re-fueling for afternoon sessions 4 strokes bikes !!!!
		Track facilities
		More pictures
		...
		End of the day... what a day. Many thanks to Jimmy.
		The K66 front after the track day. Left turn side.
		The K66 front after the track day. Right turn side. Worst then the left -> more right turns !!!
		The K66 rear after the track day. It seems better than the front !!!

Track day bike part twelve

		Some ideas for 2012  - the fork  - the front wheel  - the front brake(s)
		Could be a mix of FZR400R fork and braking system with TZR125 4FL wheel ?
		Found some plugs for the pipes... to prevent moisture to come in !!!
		My RD500-FZR400 track bike and the second hand FZR400 fork just bought.
		Lower yoke well rusted but after a little work.
		Upper yoke with a broken ignition switch bolt. A tack weldding and voila !!!!
		Upper yoke after a quick clean.
		fork legs : seals and dust seal need to be replaced. Complete fork after the little cleaning.
		Lower  T comparison Stragely the bear seats are wider on the TZR250 sterm. Decision : sterm axle swap
		Axle comparison :  - FZR400 on the left  - TZR125 on the right 125 axle can't be adapted...
		TZR wheel in FZR400.
		TZR wheel in FZR400. Twin disk setup...
		Second hand axle before and after cleaning.
		TZR125 wheel in the FZR400R fork legs. Waiting for the lower yoke to be modified.
		Removing the speedo drive.
		Replacement by an anodised alloy part (turned one).
		TZR125 wheel in the FZR400R fork legs without speedo drive.
		TZR125 wheel in the FZR400R fork legs with the FZR front mud-guard.
		I've got my FZR400 calipers and braided hoses (Philou ;-) ) Now 2 FZR400 disks..
		Front Wheel Stand
	Video	Front Wheel on the stand. Video too
		Thermo forming for making mould