YAMAHA RZV500R

We are also near the end with this two-stroke Yammy four-cylinder.

G’day! Last time we spoke we had fitted the RZV engine and it was time to sort the fuelling and exhaust, hook up the electrics and fire the RZV into life. With Covid-19 still in full force, there were some delays in progress, but eventually I got the job done and what a task it was!

Routing the wiring loom and repairing it as we went, Tim and I put a solid few days into that task alone. There is very little space and everything must be exactly as per the workshop manual. The same thing goes for the cables and, man, are there some cables on this thing! I’ve never seen anything like it in my life. Anyway, we did the job properly, lubricating all cables, routing them as per the manual and adjusting them as required.

Plugs, coils, various switches, battery, etc., came next, followed by the cooling system plumbing, which is also highly complicated, and all hoses must be routed exactly as per manual or they won’t fit. The RZV is spaghetti central. It’s more Italian than Valentino Rossi in that regard. There must be 15kg in cables and hoses!

With the wiring, cabling, lubrication system and cooling system all sorted out, the time came to fill the bike with fluids. I always get a little nervous at this point. I cleaned under the bike to make sure any drips would be visible. In went the gearbox oil, coolant including in the reservoir, plus two-stroke oil. All were bled according to the manual, with particular attention to the two-stroke oil tank and main feed line… The bike was left overnight and in the morning I’m happy to report that there were no puddles under it.

Tim arrived and we finished putting the wheels in, fitted the new chain and sprockets, and then after one last look over everything with a torch, we fuelled the bike up and turned the fuel tap to ‘Prime’ for the first time. No leaks or flooding, so that was a miracle really!

We got on the blower to Chappie and told him to get over as soon as he could. By mid-arvo he was in the shed with a cold six-pack and the moment of truth arrived. Tim hit the ignition, the powervalves rotated, he applied the choke and after a few kicks the RZV fired into life like a brand new bought one! It was cheers all round and I tell you, beer has never tasted so good. I could have poured it all over the garage floor and rolled around in it naked, such was my joy. The lads stopped me before I could get my shoes off, thankfully, and we went back to watching the RZV idle away. We were all so happy.

Another overnight check for fluid loss revealed one small coolant leak, which was rectified. I then took the bike outside to really run it properly up to temperature a few times and make sure the thermo fan worked. Everything went well, so I balanced the carburettors and got the bike idling really nicely. Now it’s time to dress the beast and run it on the streets…

Next time out and it’s the final part, where we triple check everything before dressing the RZV500R and hitting the road for a photoshoot and some fun! Can’t wait!

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8 7/ You can see how complex the cable, wiring and hose routing is and how important it is to get it right. Looks like it just came from the factory… 8/ Plug leads, coil wiring, hoses and cables all need to have clearance. Tim spent the time to get it right.

2 1/ The carburettors were bad, but not sad. A full strip, soak and blow-out, re-set and they were as good as new. 2/ Once back on the bike it was time to start routing the many cables. Ensuring the carby clamps are in the correct position is critical as once the air-box is on there is only one point you can access the clamp screws.

4 3/ Tim took his time, followed the manual and our photos, and made sure all cabling and wiring was routed exactly as per original from the factory. 4/ The pipes came up nicely. They are stock RZV with restrictions removed. They sound fantastic as they are. 5/ Chappie had to machine up a new thermo fan switch using two to make one that came on at 95 degrees rather than the stock unit that doesn’t kick in until 105 degrees. 6/ Exciting times as the fluids go in. Here Tim is filling the gearbox up. Happy days!

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14/ New chain and front and rear sprockets went on next. 15/ The bike, fuelled up and ready to start. 16/ Tim firing up the RZV; I could not kick due to a busted knee. We had Chappie over and all cracked a cold beer as soon as it fired up – first few kicks. 14

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10 9/ This is the RZV ready to have an overnight rest to see if any fluids leak. Looking good. 10/ Phil, our buddy who painted the RM80XT and RG250 HB (see this issue), painted the wheels and also the inside of the fairing, inner cowl, race cowl and a few things. The wheels came up nicely. 11/ Freshly painted rotors fitted. We cleaned up the original disc bolts. 12/ All three calipers were stripped, cleaned up, repainted and assembled with new seals, as were both front and rear mastercylinders. 13/ We used Hel brake lines, made for us by our mate that is Hel over here, Dean. Great job, easy to fit, but difficult to bleed the system with the anti-dive and so forth.

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