Track day bike project


Olivier PATROUIX
2015-06-23


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

Japanese brochure

tzr 2xt tzr 250 TZR 250 1988 2XT (not 2ma or 1kt)
Nikasil cylinder with extra exhaust port
tzr 2xt tzr 2xt Bigger reed block (8 petals)
larger rims
tzr 2xt tzr2xt Paint scheme and evolution (in Japanese)

Model identification

I've checked on the bike details that show the differences between European and Japanese model.

tzr tzr The bike arrives at home and some parts are missing : filling cap, petcock, screen and hand blisters. For sure tires are old and dry...
tzr 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 : 15mm
Right image 2ma : 12mm

Track day bike part one

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.

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

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.

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

The 2006 club event is the 1st and 2d of July. I'm working on the next stage of my "race" bike. I start fitting after-market race fairing and seat to the bike.
 

 

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 clear-coated 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

I start fitting after-market race fairing and seat to the bike almost painted
 

 

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 is painted but no clear-coat !!
Date 29 June meeting 1 & 2 of July so no more time.
 

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

Track day bike part six

Work for 2007 track session.
 

TZR125 Belgarda radiator, bigger, curved will help to keep the engine cooler
First 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

Work for 2008 track session

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 seize 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

Work for 2009 track session

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 tire after the weekend.
  Rear tire after the weekend. No problem all weekend.

Track day bike part nine

Work for 2010 track session

TZR250-fairing-bracket TZR250-fairing-bracket Old and new fairing mounting
TZR250-fairing-bracket TZR250-fairing-bracket With choke lever
TZR250-fairing-bracket TZR250-fairing-bracket With fairing.
Fuel Tank repair Fuel Tank repair Damage to be repaired. Common problem from bike of this age.
Fuel Tank repair Fuel Tank repair Metal sheet is too thin that welding is not possible.
I've cut the tank and weld a new piece of metal.
Fuel Tank repair Fuel Tank repair Need to buy oxygen to finish the welding.
Welding done and started paint stripping
Fuel Tank repair Fuel Tank repair Paint stripping.
Fuel Tank repair Fuel Tank repair More stripping and ding to be repaired
Fuel Tank repair Fuel Tank repair Other side and welded zone
TZR250-2XT-Piston_02 TZR250-2XT-Piston_04 Just bought pistons from Japan and not available anymore from Yamaha !!! even in Japan.
link to pictures
DashBoard DashBoard "Racing" dashboard
Digital temperature and shift light
Fuel Tank repair Fuel Tank repair Painted tank on the bike
Fuel Tank repair Fuel Tank repair Painted tank on the bike and YAMAHA sticker too big !!!
DashBoard   "Racing" dashboard in the fairing.
Fuel Tank repair Fuel Tank repair Sticker on tank
Fuel Tank repair Fuel Tank repair Bike ready for next weekend : track day at Magny Cours
Magny Cours 2010 RD500LC Magny Cours 2010 RD500LC 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
Magny Cours 2010 RD500LC Magny Cours 2010 RD500LC Track pictures from JP Marin

 


Track day bike part ten

Work for 2011 track session

 

TZR 2XT rebuild TZR 2XT rebuild Engine rebuild due to break down during last track session.
TZR 2XT rebuild TZR 2XT rebuild Striping it down.
TZR 2XT rebuild TZR 2XT rebuild Engine out of the frame.
TZR 2XT rebuild TZR 2XT rebuild Engine on the desk.
TZR 2XT rebuild TZR 2XT rebuild Head OK no carbon no marks.
Right piston nice top no mark in cylinder.
TZR 2XT rebuild TZR 2XT rebuild Left piston nice top but marks in cylinder.
Look like a bearing as gone : big end or crank...
TZR 2XT rebuild TZR 2XT rebuild Cylinder with marks !!!
TZR 2XT rebuild TZR 2XT rebuild Cleaned engine and 2XT read intake.
TZR 2XT rebuild TZR 2XT rebuild Engine on the desk ready for pouring gear box oil.
TZR 2XT rebuild TZR 2XT rebuild Used spare crank
TZR 2XT rebuild TZR 2XT rebuild Cleaned head and right dome.
TZR 2XT rebuild TZR 2XT rebuild Left dome with marks (small ones).
TZR 2XT rebuild TZR 2XT rebuild good clean to the done (left have small park).
TZR 2XT TZR 2XT Left damaged cylinder.
TZR 2XT TZR 2XT Left damaged cylinder & right cylinder (on the right).
TZR 2XT TZR 2XT Right undamaged cylinder.
TZR2XT Piston TZR2XT Piston 2XT pistons : right OK / Left KO.
TZR 2XT rebuild TZR 2XT rebuild 2XT read valves : 8 petals.
TZR 2XT rebuild TZR 2XT rebuild Clutch and clutch case.
TZR 2XT rebuild TZR 2XT rebuild Damaged big end bearing with copper pieces from the conrod !!!
TZR 2XT rebuild TZR 2XT rebuild Metal pieces !!!
Red circle = metal pieces.
TZR 2XT rebuild TZR 2XT rebuild Metal pieces !!!
TZR 2XT rebuild   Metal pieces again !!!
TZR250 2XT TZR250 2XT One half of the crank is gone.
TZR250 2XT TZR250 2XT Big end gone close up.
Spare crank need an overhaul too.
TZR250 2XT TZR250 2XT Crank case with big end marks.
TZR250 2XT TZR250 2XT TZR 2XT intake with room for tuning !!!!.
TZR250 2XT TZR250 2XT While waiting for the price of crank rebuild, I've cleaned the edge of the crank case on the intake.
TZR250 2XT TZR250 2XT I've cleaned the edge and rounded the corners.
TZR250 2XT TZR250 2XT Here are other views.
Don't know if I need to do further.
TZR250 2XT TZR250 2XT Here are picture of 2XT tuning by ToshTec in Japan (Assy Blog 1 & 2 & 3).
 
TZR250 2XT TZR250 2XT Checking how the intake, cylinder and case match !!!
TZR250 2XT TZR250 2XT Some small zones where improvements can be done !!!
TZR250 2XT TZR250 2XT Other views but not sure this time and effort will lead to noticeable improvement.
TZR250 2XT exhaust   I've seen that the exhaust diameter could by enlarge to suit JollyMoto diameter.
Shipping Crank   Crank ready to be shipped to RoadAndDirt Performance Bike Part in the UK
2XT Piston 2XT Piston Piston arrive from Japan (Thanks Nao).
Small custom cost but OK
Need to buy piston pin and clip
2XT Piston 2XT Piston Measurements : 56.35mm
Play : 0.05mm
TZR250 2XT TZR250 2XT 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.
2XT reed gasket pattern 2XT reed gasket pattern Spacer for cutting the reed paper seal.
CAD file -> CNC Cutting
2XT reed gasket pattern 2XT reed gasket pattern A good basis for cutting the paper seal not included in the 1KT or 2MA gasket kits.
piston pin   Yamaha parts for the top end rebuild
JollyMoto JollyMoto JollyMoto pipes o'ring rebuild.
JollyMoto JollyMoto JollyMoto pipes oring rebuild.
Unrusted & ready to be painted.
JollyMoto JollyMoto JollyMoto been painted.
JollyMoto JollyMoto Close view.
JollyMoto JollyMoto Not bad for 15years old pipes.
TZR250 clutch TZR250 clutch Clutch cover cleaned.
Oil filter too.
TZR250 2XT Piston 2XT Crank rebuild
Piston kits
tzr 250 2xt tzr 250 2xt Yamaha crank seals
tzr 250 2xt tzr 250 2xt Crank cases closed
Pistons on the conrod
tzr 250 2xt tzr 250 2xt Cylinders on
tzr 250 2xt tzr 250 2xt Head gasket with Loctite 3020
tzr 250 2xt tzr 250 2xt Head in place
Engine in the frame
tzr 250 2xt tzr 250 2xt Radiator and JollyMoto pipes
tzr 250 2xt tzr 250 2xt Missing intake manifolds
coupler Fuel tap 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 ?
Fuel tap Fuel tap Dismantled fuel tap
Not lot of space for enlargement.
Fuel tap Fuel tap The bike has run on the 2 cylinders.
Fuel circuit on the bike.
Heat cycles done => ready for track day.
TZR 250 2xt TZR 250 2xt RD500LC French Club meeting done without any problems : nor on the engine or the fuel system
ILoveMotor ILoveMotor Thanks to RoadAndDirt for the crank service (Hi Dave)
Bike with ILoveMotor stickers on.
TZR 250 2XT on track TZR 250 2XT on track Track pictures by JP Marin

 


Track day bike part eleven

Work for 2011 track session at PAU
http://www.circuit-pau-arnos.fr/
With Jimmy Sallaberry rider as "instructor" (http://www.sr-team.fr/) and thanks to Corexpert sponsoring (http://corexpert.net)
 

 

TZR 2XT rebuild TZR 2XT rebuild Old fairing bracket broken during Magny Cours session.
TZR 2XT rebuild TZR 2XT rebuild New bracket in progress made in stainless steel.
TZR 2XT rebuild TZR 2XT rebuild Welding and tachometer mount to be added.
TZR 2XT rebuild TZR 2XT rebuild Here is the bracket.
Welding is not perfect but I hope this will be OK.
TZR 2XT rebuild TZR 2XT rebuild Other views.
TZR 2XT rebuild TZR 2XT rebuild Mounted.
Heidenau K66 Heidenau K66 New tyres ordered
Heidenau K66
 - front in 100/80 compound CUP
 - rear in 130/70 compound std.
Heidenau K66 Heidenau K66 Maybe more a all season tire but it is a test and will be OK for winter track session!!!
Heidenau K66 Heidenau K66 Fitted by Meca Moto Service in Anglet.
M├ęca Moto Service
Heidenau K66 Heidenau K66 Nice thread.
 
Heidenau K66 Heidenau K66 Read for Autumn track days !!!!
Fork tube Fork tube Pitted fork on my 2XT so tube will be changed.
Here donor front end (2MA one)
Fork tube Fork tube Close views.
Fork tube Fork tube Dismantling :
 - It was time to do !!!
 - tube is OK.
Fork tube Fork tube Dismantling :
 - Oil damper problem!!!
 - second leg OK
Fork tube   Dismantling :
 - tube is OK
Fork tube Fork tube Dismantling TZR 2XT:
 - fairing
 - pitted leg
Fork tube Fork tube Dismantling TZR 2XT:
 - pitted leg
 - leaking seal
 - cracked dust seals!!!!
Fork tube Fork tube Dismantling TZR 2XT:
 - no front end bike!!!!
 - Left leg dismantled
Fork tube Fork tube 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
 
Fork tube Fork tube Differences  2XT / 2MA
 - 2XT left / 2MA right
   - damper rod (bottom)
      - 2 holes 6.9mm on 2XT
      - 1 hole 7.9mm on 2MA
Fork tube   Differences  2XT / 2MA
 - 2XT left / 2MA right
   - damper rod (top)
      - 1 holes 2.5mm on 2XT
      - 1 hole 1.5mm on 2MA
Fork tube Fork tube Differences  2XT / 2MA
 - 2XT left / 2MA right
   - spring :
      - 427mm on 2XT
      - 421mm on 2MA
Fork tube Fork tube Rebuild on a wooden bench ;-) :
      - 2MA damper rods
      - 2XT springs
      - new seals
Fork tube Fork tube       - 2MA dust seals
      - oil SAE15W
Forks done no oil.
Fork tube Fork tube BlueOil fork oil
      - 450cc per leg
Front end back on the bike
TZR 250 2xt ready to Pau TZR 250 2xt ready to Pau Upper fairing on the bike
Next a warming up...
TZR 250 2xt ready to Pau TZR 250 2xt ready to Pau Here some pictures of the bike ready to go on the trailer
TZR 250 2xt ready to Pau TZR 250 2xt ready to Pau Some new stickers
TZR 250 2xt ready to Pau TZR 250 2xt ready to Pau Jimmy's paddock hospitality and van
TZR 250 2xt ready to Pau TZR 250 2xt ready to Pau Bike on the rear stand.
My friend trying to follow Jimmy!!!
TZR 250 2xt ready to Pau TZR 250 2xt ready to Pau Some morning pictures
TZR 250 2xt ready to Pau TZR 250 2xt ready to Pau After session debriefing...
Lot to say on trajectories
TZR 250 2xt ready to Pau TZR 250 2xt ready to Pau Re-fueling for afternoon sessions
4 strokes bikes !!!!
TZR 250 2xt ready to Pau TZR 250 2xt ready to Pau Track facilities
TZR 250 2xt ready to Pau TZR 250 2xt ready to Pau More pictures
TZR 250 2xt ready to Pau TZR 250 2xt ready to Pau ...
TZR 250 2xt ready to Pau TZR 250 2xt ready to Pau End of the day... what a day.
Many thanks to Jimmy.
TZR 250 2xt ready to Pau TZR 250 2xt ready to Pau The K66 front after the track day.
Left turn side.
 
TZR 250 2xt ready to Pau TZR 250 2xt ready to Pau The K66 front after the track day.
Right turn side.
Worst then the left -> more right turns !!!
TZR 250 2xt ready to Pau TZR 250 2xt ready to Pau The K66 rear after the track day.
It seems better than the front !!!

 


Track day bike part twelve

Work for 2012

 

TZR 250 2xt ready to Pau TZR 250 2xt ready to Pau Some ideas for 2012
 - the fork
 - the front wheel
 - the front brake(s)
TZR 250 2xt ready to Pau TZR 250 2xt ready to Pau Could be a mix of FZR400R fork and braking system with TZR125 4FL wheel ?
pipe plug pipe plug Found some plugs for the pipes... to prevent moisture to come in !!!
TZR 250 2xt ready for 2012 TZR 250 2xt readyfor 2012 My RD500-FZR400 track bike and the second hand FZR400 fork just bought.
TZR 250 2xt ready for 2012 TZR 250 2xt readyfor 2012 Lower yoke well rusted but after a little work.
TZR 250 2xt ready for 2012 TZR 250 2xt readyfor 2012 Upper yoke with a broken ignition switch bolt.
A tack weldding and voila !!!!
TZR 250 2xt ready for 2012 TZR 250 2xt readyfor 2012 Upper yoke after a quick clean.
TZR 250 2xt ready for 2012 TZR 250 2xt readyfor 2012 fork legs : seals and dust seal need to be replaced.
Complete fork after the little cleaning.
TZR 250 2xt ready for 2012 TZR 250 2xt readyfor 2012 Lower  T comparison
Strangely the bear seats are wider on the TZR250 stem.
Decision : stem axle swap
TZR 250 2xt ready for 2012 TZR 250 2xt readyfor 2012 Axle comparison :
 - FZR400 on the left
 - TZR125 on the right
125 axle can't be adapted...
TZR 250 2xt ready for 2012 TZR 250 2xt readyfor 2012 TZR wheel in FZR400.
TZR 250 2xt ready for 2012 TZR 250 2xt readyfor 2012 TZR wheel in FZR400.
Twin disk setup...
TZR 250 2xt readyfor 2012 TZR 250 2xt ready for 2012 Second hand axle before and after cleaning.
TZR 250 2xt readyfor 2012 TZR 250 2xt ready for 2012 TZR125 wheel in the FZR400R fork legs.
Waiting for the lower yoke to be modified.
TZR 250 2xt readyfor 2012 TZR 250 2xt ready for 2012 Removing the speedo drive.
TZR 250 2xt readyfor 2012 TZR 250 2xt ready for 2012 Replacement by an anodized alloy part (turned one).
TZR 250 2xt readyfor 2012 TZR 250 2xt ready for 2012 TZR125 wheel in the FZR400R fork legs without speedo drive.
TZR 250 2xt readyfor 2012 TZR 250 2xt ready for 2012 TZR125 wheel in the FZR400R fork legs with the FZR front mud-guard.
TZR 250 2xt readyfor 2012 TZR 250 2xt readyfor 2012 I've got my FZR400 calipers and braided hoses (Philou ;-) )
Now 2 FZR400 disks..
TZR 250 2xt readyfor 2012 TZR 250 2xt readyfor 2012 Front Wheel Stand
TZR 250 2xt readyfor 2012 Video Front Wheel on the stand.
Video too
Thermo Folding Thermo Folding Thermo forming for making mold
TZR 250 2xt readyfor 2012 TZR 250 2xt readyfor 2012 Many thanks Philou for these TDM rotors ....

Track day bike part thirteen

Work for MC 2012
 

Onboard camera TZR250 Onboard camera TZR250 Camera Mounting looking rear
Prototype
Onboard camera TZR250 Onboard camera TZR250 Camera Mounting looking front
Alloy part
Onboard camera TZR250 Onboard camera TZR250 Camera Mounting looking rear
And final mounting on the rear.
Onboard camera TZR250 Onboard camera TZR250 Camera Mounting looking front
And final mounting on the front.
Onboard camera TZR250 Onboard camera TZR250 Camera Mounting looking front/rear
Onboard camera TZR250 Onboard camera TZR250 On-board views front & rear
Video to come
TZR250 peg TZR250 peg Cleaned LH foot-peg
Greased and adjusted
TZR250 peg   Cleaned RH peg
TZR250 peg TZR250 peg HT painted pipes
Left & Right
TZR250 peg TZR250 peg Seat
Front quick fasteners
TZR250 peg TZR250 peg Seat
Rear quick fastener
Fox Racing Taldea   FOX RACING TALDEA
Identification
Private testing Private testing FOX Racing Taldea private testing !!!
Faring TZ TZR250 Faring TZ TZR250 Alloy grid on lower fairing
Faring TZ TZR250 Faring TZ TZR250 Alloy grid on lower fairing on the bike
Faring TZ TZR250   Alloy grid on lower fairing on the bike
Faring TZ TZR250 Faring TZ TZR250 Bike ready for RD500LC Club meeting by the end of June 2012...
MC 2012 MC 2012 See : MC 2012

 


Track day bike part fourteen

Work for 2013
 

 

FZR400 2 TZR250 FZR400 2 TZR250 FZR400R Fork adaptation
Grinding welding and pressing axle out
FZR400 2 TZR250 FZR400 2 TZR250 Job done on TZR T
FZR400 2 TZR250 FZR400 2 TZR250 TZR axle ready to weld on FZR T
FZR400 2 TZR250 FZR400 2 TZR250 Cleaned and ready for primer
FZR400 2 TZR250 FZR400 2 TZR250 In primer
FZR400 2 TZR250 FZR400 2 TZR250 In metallic silver (Vito Van paint)
FZR400 2 TZR250 FZR400 2 TZR250 Dried.
FZR400 2 TZR250 FZR400 2 TZR250 With clear varnish on.
FZR400 2 TZR250 FZR400 2 TZR250 With top triple T.
On fork.
TZR 250 2xt readyfor 2012   Upper T sanded and stock clip-ons.
Painted FZR400 upper T Painted FZR400 upper T Upper T painted in silver
Painted FZR400 upper T Painted FZR400 upper T Upper T painted in clear varnish
FZR400 clip-on FZR400 clip-on Left hand (throttle) slightly bent.
Un-bent in the vice so a little mark but will not seen after with grip.
FZR400 clip-on FZR400 clip-on The result and painted in primer.
FZR400 clip-on FZR400 clip-on Left hand in primer.
FZR400 clip-on FZR400 clip-on Right hand in primer.
YamBits Lines YamBits Lines YamBits fuel line kits for the carb.
http://yambits.co.uk/
Quuick coupler in 8mm   New 8mm fuel coupler to replace 6mm one !!!
2XT carb. 2XT carb. Carburetor cleaning.
2XT carb. 2XT carb. Carburetor cleaning.
Is this air-jet common on 1KT/2MA or specific to 2XT (Maybe FIII mod).
Float height is 17.50mm.
2XT carb. 2XT carb. Carburetor cleaning.
Plastic fuel filter gets crap!!!
2XT carb. 2XT carb. Carburetor cleaning.
Power-jet dismantled.
2XT carb. 2XT carb. Carburetor cleaning.
Carb bowl ready to reassemble.
Carbs done.
Cleaned airfilter Cleaned airfilter Cleaned air filter and oily again.
2XT carb. 2XT carb. Carburetor cleaning.
News vent and overflow hoses...
2XT carb. 2XT carb. Carburetor cleaning.
Float set to 16mm and new fuel hoses...
YamBits Lines YamBits Lines Fuel line 8mm the tank.
YamBits Lines YamBits Lines Fuel filter on line 6mm.
Quick coupler as petcock.
2XT carb. 2XT carb. Carb. back on the bike.
2XT carb. 2XT carb. Airbox back too and bike running.

Pau track day
 

Pau 2012 TZR 250 Pau 2012 TZR 250 Ready for the trailer.
Pau 2012 TZR 250 Pau 2012 TZR 250 Dashboard control..
Pau 2012 TZR 250 Pau 2012 TZR 250 Nice day at Pau..
Pau 2012 TZR 250 Pau 2012 TZR 250 Single exhaust TZR !!!
Martin77 pipes on soon.
Pau 2012 TZR 250 Pau 2012 TZR 250 Paddock tour mostly diesels!!!
Pau 2012 TZR 250 Pau 2012 TZR 250 Nice single using KR1 frame with Aprilia engine.
Pau 2012 TZR 250   RAK =>Rotax Aprilia Kawasaki.
Pau 2012 TZR 250 Pau 2012 TZR 250 At the end some 2 strokers with KR1.

 


Track day bike part fifteen

Work in 2013
 

 

FZR400 2 TZR250 FZR400 2 TZR250 Adaptation fork FZR400R
 R6 fork cap.
FZR400 2 TZR250   Comparison R6 FZR400R
FZR400 2 TZR250 FZR400 2 TZR250 R6 cap on the fork
Fork parts   TZR steering bearings
FZR fork seals and dust seals
TZR-FZR fork swap TZR-FZR fork swap TZR fork off
TZR-FZR fork swap TZR-FZR fork swap TZR fork off
Lower bearing on the TZR-FZR lower T
TZR-FZR fork swap TZR-FZR fork swap Top steering bearing on the frame
Lower T on the frame
TZR-FZR fork swap TZR-FZR fork swap Upper T on the bike
Draft fork fitment on the bike
TZR-FZR fork swap TZR-FZR fork swap Draft fork fitment on the bike
Upper fairing on
TZR-FZR fork swap TZR-FZR fork swap View from rider seat
With clip-on on
TZR-FZR fork swap TZR-FZR fork swap With clip-on in primer
Standard FZR400R front end
TZR-FZR fork swap TZR-FZR fork swap Standard FZR400R front end
TZR-FZR fork swap TZR-FZR fork swap Bike in horizontal position
Wheelbase : 1374mm
SwingArm axle height : 382mm
Attention : garage ground in not fine.
TZR-FZR fork swap TZR-FZR fork swap Fork T height : 920mm
Attention : garage ground in not fine
TZR-FZR fork swap TZR-FZR fork swap Bike in horizontal position
10mm offset difference
TZR-FZR fork swap TZR-FZR fork swap Upper fairing on
TZR-FZR fork swap XJR1300 R6 FZR400 fork Upper fairing on.
XJR1300 and R6 fork caps.
XJR1300 R6 FZR400 fork XJR1300 R6 FZR400 fork In the center, the FZR400R standard setup without any tuning setup.
XJR1300 R6 FZR400 fork XJR1300 R6 FZR400 fork From left to right, XJR, FZR400 and R6.
XJR fork cap installed.
XJR1300 R6 FZR400 fork XJR1300 R6 FZR400 fork Installed and tuned for the FZR400 to be adjusted for the TZR250.
Android bubble setup !!! Android bubble setup !!! Android Bubble level application to setup the chassis !!!
Swing arm angle 11.3° / 11.2°
Android bubble setup !!! Android bubble setup !!! Android Bubble level 1° error ?
To be calibrated more accurately
Android bubble setup !!! Android bubble setup !!! Front castor angle 90°-62° = 28°.
Should be near to 26°.
To be calibrated more accurately
Double dogbones TZR250 2XT Double dogbones TZR250 2XT Double dogbones cut in PVC sheet for testing (CNC).
2 positions 107mm & 102mm (original 112mm)
Double dogbones TZR250 2XT Double dogbones TZR250 2XT Double dogbones cut in PVC sheet for testing.
Double dogbones TZR250 2XT Double dogbones TZR250 2XT Double dogbones on the bike at larger position : 107mm between holes
Double dogbones TZR250 2XT   Front fork castor : 68-69° (angle application not calibrated)
Double dogbones TZR250 2XT Double dogbones TZR250 2XT Double dogbones on the bike at smaller position : 102mm between holes
Double dogbones TZR250 2XT   Front fork castor : 67-68° (angle application not calibrated)
Double dogbones TZR250 2XT Double dogbones TZR250 2XT Made 103mm dogbone to be able to :
  • seat on the bike
  • make some measurements
Double dogbones TZR250 2XT Double dogbones TZR250 2XT Made some plastic spacers for the handle bars.
Double dogbones TZR250 2XT Double dogbones TZR250 2XT Bubble level to calibrate the mobile phone application.
Double dogbones TZR250 2XT Double dogbones TZR250 2XT Horizontal measurements is 1-2° but to be added or subtracted .
Double dogbones TZR250 2XT Double dogbones TZR250 2XT Measurements on the bike (wheels on the ground) :
  • Rear arm 8° => 10°
  • Front fork 68° => 66°
Double dogbones TZR250 2XT   Bike vertical
Balance :
  • castor angle : 24°
extended fork TZR FZR extended fork TZR FZR Fork fully extended
  • left 131mm
  • right 131mm
SAG will be calculated from there.

 


Track day bike part sixteen

  Work in 2013

 

Brake lines+++ Brake lines+++ Hel Brake lines
 - front & rear for FZR400R
Brake lines+++ Brake lines+++ Hel Brake lines
 - on master cylinder
 - left hand caliper
Brake lines+++ Brake lines+++ Hel Brake lines
 - right hand caliper
Ready for new brake fluid
Brake lines+++ Brake lines+++ New DOT 4 fluid back in
Maser cylinder where it should be !!!
Brake lines+++ Brake lines+++ Right & Left caliper on fork legs with pads in.
Brake lines+++   Front looks like a bike again.
Thanks Peio
TZR & FZR TZR & FZR Clip-on silver painted and clear coated.
Also fairing bracket from black to silver.
TZR & FZR   Fairing back on... better view.
TZR & FZR TZR & FZR Fork dismantled
TZR & FZR TZR & FZR PVC tube heated to make a seal tooling.
Lower leg ready for primer.
TZR & FZR TZR & FZR Lower leg in primer
TZR & FZR TZR & FZR Lower leg ready for metal silver paint.
TZR & FZR TZR & FZR Fork legs painted and ready for clear coating.
TZR & FZR TZR & FZR Lower leg ready for primer and in clear coated.
TZR & FZR TZR & FZR Lower leg in clear coated
TZR & FZR TZR & FZR Lower leg ready for rebuilding.
TZR & FZR TZR & FZR  FZR400RR 3TJ
43mm Fork Tubes
Fork Spring Free Length - 346mm
Minimum - 341mm
Spring Rate - 6.5N/mm (0.65Kg/mm)
Fork Travel - 120mm
TZR & FZR TZR & FZR Home made tool for locking the plunger
TZR & FZR TZR & FZR Fork  on the tooling ;-)
Fitting the slider and spacer
TZR & FZR TZR & FZR Fitting the seal.
Fork legs back in one piece.
TZR & FZR TZR & FZR 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)
TZR & FZR TZR & FZR Fork  on the bike again ;-)
 
K66 Heidenau tire K66 Heidenau tire Front tire ordered to replace the old BT45
Heidenau K66 in 110/70x17 on the way.
Arrived 23/05/2013 (with Yamaha Chappy set ;-) )
Thermo forming for making mold
Thanks Denis ;-)
TZR & FZR TZR & FZR Little sun shine so outside pictures :
front views.
 
TZR & FZR TZR & FZR Little sun shine so outside pictures :
front views.
 
Mold and first trial of carbon kevlar front mudguard.
Thermo forming for making mold
Carbon fender FZR400 Far from perfect but will see ;-).
Thanks Francis ;-)
Carbon fender FZR400 Carbon fender FZR400 Out of the mold.
Quick deburring  and fit on the fork
 
Carbon fender FZR400   Fit on the fork.
Not that bad for my first part
;-)
 
K66 Heidenau tire K66 Heidenau tire Ready to be fitted...
K66 Heidenau tire K66 Heidenau tire And voila !!!
Thanks Flop ;-)
FZR-TZR front end TZR250 + FZR400 Front end ready
TZR250 + FZR400 TZR250 + FZR400 The upper fairing on.
TZR250 + FZR400   Almost good.
01-06-2013
double dogbones double dogbones Double dogbones made in 4mm steel and laser cut...
Thanks Georgy ;-)
double dogbones double dogbones DogBone on the bike and hop now ready for nickel plating.
Plating done thanks Peio ;-)

 


Track day bike part seventeen

  Work in 2013

 

TZR250-TZR50 Tank TZR250-TZR50 Tank TZR 50 fuel tank project
Manage to buy a NOS TZR50 tank
TZR250-TZR50 Tank TZR250-TZR50 Tank Will do the same modification as my friend Peio
http://rd500lc.free.fr/forum/TZR50-Tank/
TZR250-TZR50 Tank TZR250-TZR50 Tank FZR400 fuel outlet
GIMP picture to check paint scheme
TZR250-TZR50 Tank   Tank in the sun shine !!
TZR250-TZR50 Tank TZR250-TZR50 Tank Tank on the bike.
TZR250-TZR50 Tank TZR250-TZR50 Tank Much narrow than the original one.
Seat back on to check.
TZR250-TZR50 Tank   3/4 rear view.
Bracket for TZR50 tank Bracket for TZR50 tank Fuel tank bracket modification.
Welding grinding.
Bracket for TZR50 tank Bracket for TZR50 tank Widening tuning.
Bracket for TZR50 tank Bracket for TZR50 tank Ready for the new welding
Bracket for TZR50 tank Bracket for TZR50 tank
 
Plates welded on.
Bracket for TZR50 tank Bracket for TZR50 tank
 
Ungreasing / phosphating before painting.
Bracket for TZR50 tank Bracket for TZR50 tank
 
Ready for painting.
Bracket for TZR50 tank Bracket for TZR50 tank
 
Ready for painting.
Bracket for TZR50 tank Bracket for TZR50 tank In primer.
Painted in Vito Metal gray
Bracket for TZR50 tank Bracket for TZR50 tank Painted in Vito Metal gray
Bracket for TZR50 tank Bracket for TZR50 tank Clear coated...
Bracket for TZR50 tank Bracket for TZR50 tank Front bracket installed on the frame...
TZR250-TZR50 Tank TZR250-TZR50 Tank Front mounting on the tank.
TZR250-TZR50 Tank TZR250-TZR50 Tank Rear mounting on the tank.
TZR250-TZR50 Tank TZR250-TZR50 Tank Fuel tank on the bike.
To be adjusted or redesigned with the front fitted ;-)
TZR250-TZR50 Tank TZR250-TZR50 Tank Test with FZR400RR seat but will not go.
Tank fitted in the front.
TZR250-TZR50 Tank TZR250-TZR50 Tank Rear mounting to be made again as expected...
FZR petcock fits perfect
TZR250-TZR50 Tank TZR250-TZR50 Tank New mounting setup
TZR250-TZR50 Tank TZR250-TZR50 Tank Side view
CNC PVC rear bracket
TZR250-TZR50 Tank TZR250-TZR50 Tank Mounting bracket
TZR250-TZR50 Tank TZR250-TZR50 Tank Mounting bracket
TZR250-TZR50 Tank TZR250-TZR50 Tank Tank back on the bike
Good line up
TZR250-TZR50 Tank TZR250-TZ Seat With the seat on.
Paint sanded
TZR250-TZR50 Tank TZR250-TZ Seat Paint sanded
TZR250-TZR50 Fairing TZR250-TZ Fairing Lower Fairing sanded
TZR250-TZR50 Fairing TZR250-TZ Fairing Upper Fairing sanded
TZR250-TZR50 Fairing TZR250-TZ Fairing Fairing and seat in primer
TZR250-TZR50 Fairing TZR250-TZ Fairing Fairing and seat in primer but sanded
TZR250-TZR50 Fairing TZR250-TZ Fairing Fairing with the white zone masked
TZR250-TZR50 Fairing TZR250-TZ Fairing Seat painted but no clear coat
TZR250-TZR50 Fairing TZR250-TZ Fairing Fairing painted but no clear coat
TZR250 2XT Carb TZR250 2XT Carb Carb cleaning with ultrasonic machine
TZR250 2XT Carb TZR250 2XT Carb One looks almost new
TZR250 2XT Carb TZR250 2XT Carb One still not as good as new but machine can do more.
TZR250 2XT Carb TZR250 2XT Carb Yamaha seat valve kit for RZ350
ref : 48H-14107-28
Same as TZR250.
TZR250 2XT Carb TZR250 2XT Carb Aftermarket carb rebuilt kit
Will do a little review.
TZR250 Rear Wheel TZR250 Rear Wheel Rear wheel painted in mat black.
Quickly done but OK
TZR250-TZR50 Fairing TZR250-TZ Fairing Fairing and seat on the bike
TZR250-TZR50 Fairing TZR250-TZ Fairing Lower fairing on.
TZR250-TZR50 Tank TZR250-TZ Seat Stickers on the seat
TZR250-TZR50 Tank TZR250-TZ Seat Stickers on the seat
TZR250-TZR50 Fairing TZR250-TZ Fairing Stickers on the fairing
TZR250-TZR50 Fairing TZR250-TZ Fairing Stickers on the fairing
Logo TZR250
TZR250-TZR50 Fairing TZR250-TZ Fairing Stickers on left lower fairing
Logo Yamaha
TZR250-TZR50 Fairing TZR250-TZ Fairing Stickers on the right lower fairing
TZR250-TZR50 Fairing TZR250-TZ Fairing Stickers on the nose cone
TZR250-TZR50 Fairing TZR250-TZR50 Fairing Look racing of the garage
Now clear coated
TZR250-TZR50 Fairing TZR250-TZR50 Fairing Right side
TZR250-TZR50 Fairing TZR250-TZR50 Fairing Left side
TZR250 2XT Carb TZR250 2XT Carb Fuel level checked.
Looks OK.
TZR250 2XT Carb TZR250 2XT Carb 4 petals 2XT reed valves.
Intake boots
TZR250 2XT Carb TZR250 2XT Carb Carb back on the bike.
Airbox on.
Oil Line kits Oil Line kits Clear oil line kits from YamBits.
Rebuild started.
Oil Line kits Oil Line kits Clear oil line kits from YamBits.
Blue oil coming from the pump.
TZR250-TZR50 Fairing TZR250-TZR50 Fairing Try a nose cone line?

Track day bike part eighteen

  Work in 2015

TZR250 2XT Carb cleaning TZR250 2XT Carb cleaning

Carburettor cleaning with ultrasonic machine

Not dirty but better to start trackday session.

TZR250 2XT Carb cleaning TZR250 2XT Carb cleaning Better loking ones.
TZR250 2XT Carb cleaning TZR250 2XT Carb cleaning

Carb back on the bike.

Started like a charm !!!

Temp Gauge 2XT Temp Gauge 2XT

Temperature unit

New cheap digital gauge

Temp Gauge 2XT Temp Gauge 2XT Dashboard form style
Temp Gauge 2XT Temp Gauge 2XT

Sender on the head.

Some electronics noise.

Temp Gauge 2XT Temp Gauge 2XT

No more noise.