Project TZR......................................
Charlie’s almost at the start line... which is a step closer to the finish line.
T he clock is ticking so I’m pleased to say that the first of the three stages of my TZR project is just about complete. The first stage has been the build of a 1988 TZR250 2MA out of a variety of boxes of parts lying around our workshop, and the rolling frame of a similar project that Beej started (and stopped…) some five years ago. I am missing only one crucial part currently in development: a bespoke radiator hose from Samco, which is in the post, so I can now start planning for stages Two and Three, the latter being a race on this bike against the field of Yamaha Past Masters (YPMs) around the Snetterton 300.
Getting to this point has been a long road of sourcing new parts, cleaning and servicing old ones and calling in favours. The biggest thus far, apart from getting the green light from Fast
Bikes’ Beej to build and race his old bike, was a package from Paul Traylen in Jersey containing a 2MA tank, giving me permission not only to use it, but also paint it, meaning the clean white race bike pictured here did not have to come complete with a yellow and red retro style tank.
I have to admit to being very excited by this; it looks stunning and has come a long way over the past six issues since the rolling frame, complete with upgraded Maxton Suspension and rebuilt engine (which is as far as Beej had got), was rolled into Phoenix Yamaha’s van.
The Trowbridge-based dealership not only allowed me a spare bench but also the services of chief mechanic Wayne Philips to aid me on the build. I am exceedingly thankful for both, having learnt so much across the build; getting my hands dirty on occasion, sourcing and supplying replacement parts and receiving a certain amount of abuse for not putting the milk in the tea before the hot water (Too right, too, and the same goes for coffee, we’re not savages – BJ).
With the exception of the hose linking the engine to the new GPI aluminium radiator all else was finished off last week. A hose could be fashioned of course, but Samco said they would make me one and given the fact that most of the YPM paddock uses this upgraded radiator it’s a very small legacy that I can leave behind at the end of this project. Wayne, having returned from injury and then his holidays, was met with his service schedule with ‘TZR day’ already written in. In the corner of the workshop he was greeted by all of the necessary parts for the final push, and what I am sure was the equally welcoming sight of me for the entire day, taking pictures, asking ‘what’s that?’ and making plenty of tea – milk first…
The fairing prep’ had been down to me. As stated in the last issue, with the help of fellow YPM’er Gary Button we had cut the race fairing from Bardney Racing in half, hinging it for ease of access. The sides had come complete with dzus fastenings to the cockpit – leaving only the seat unit to be strengthened with 3mm aluminium plates at the rear (and under the seat) so that it won’t flex when riding.
A seat pad was pinched from JHS Racing and glued into position, two holes burnt through the seat by heating a copper pipe and melting through the foam to produce two perfect holes, allowing access to the bolts that secure the unit into position on the purpose built brackets. Finally the ‘two-stroke’ green number boards fore and aft were sprayed on using Halfords spray paint and a final layer of lacquer, to protect the paint from the potential of peeling with the application (and more appropriately, removal) of race numbers.
I also had some paperwork to do, getting my race application in and number for the finale of this project. #99 has been allocated, which lead to much hilarity in the workshop with expectancy that it would read as #66 once I am on track. Har-bloody-har…
So back in Trowbridge we were ready to get things finished. First job was to fit the chain allowing us to run through the gearbox proficiently enough to make sure we had them all. The SES rear-sets are superb, giving a lot of feel through this near 30-year-old gearing. The side-stand is in the way (of course) but that is still in place for ease in the workshop. We had a slight issue with the rear calliper, fresh from Hong Kong via eBay, but a tightening of the bolts and bleed from both nipples released the air allowing a build up of pressure. Once done a hose replaced the reservoir and it was sorted.
Moving forward, the oil pump was disconnected from the throttle and the feeder pipes doubled back to create a seal so that no air could be sucked into the carbs. All that is left now is the aforementioned radiator hose and we are ready to run.
Fitting the fairing took some time. With no pre-supplied brackets we managed to find a few in the Phoenix Yamaha ‘spares box’ which given some filing, drilling and manipulation allowed the fairing to all come together, tight to the frame of the bike, fitting beautifully. You may remember that this fairing had come from Bardney Racing, prepared from a cast provided by a member of the YPM faithful, so I had no doubt it would fit well, but it’s genuinely perfect.
While all of this was going on the manager of the dealership – Barry Bear – was getting involved having offered to prepare the tank for me. There were rust spots that he treated, sanded, filled and sanded again. Then he proceeded to spray the unit white, thus finishing off perfectly what you see here. This is a bike that I am immensely proud of and cannot wait to move into stage two – the testing. With a trackday booked at Castle Combe, I will have plenty of opportunity to run the bike in and test its capabilities, though this will only leave one month to get it finely tuned and race ready before Snetterton.
So far, so good, but there are quite a few bridges to cross before the racing. Looking good is one thing, performing well will be another considering that I’ll be gridding against 32 TZRs that pretty much have a full season behind them. With all the investment, time and generosity shown to me for this project. stage two is crucial. Phoenix have helped me to build a runner, I am asking JHS Racing to make it a racer, and when the red lights go out at Snetterton it will be down to me to bring all of these things together. Deep breaths, Charlie, deep breaths…