RZ250 Rebuild!

[casabonka]

Hi Guys,
Long time lurker who purchased a complete, but neglected RZ250 3 years ago.

After pulling it apart, I bought a boat and lost motivation to do the rebuild...

Move forward a year and I got the frame powdercoated, and then Covid hit and lost motivation again.

Now finally, the rebuild has started after shipping everything off to the Father in Law who has decades of experience building bikes!

The main drama Im having is with the Fuel tank - she's pretty cactus. I've heard mixed reviews of the indian built tanks, and if it does need some small modifications, this shouldn't be too bad.


Ordered a new windscreen, shock parts and waiting on that, and now just the slow process of getting it back to a rolling frame.

Feel free to share your horror stories or tips, and I'll try to keep this updated as much as possible!

[casabonka]

Here's a couple of happy snaps

Day One




Starting the pull-down


Powdercoating complete!

[JonW]

Welcome!

Build looks to be progressing which is great.

Hmm.... There are no 'mixed reviews' of Indian tanks. Its very clear cut. Do not waste your money.

Have a good read around this and other forums for good info on what to buy and what not to.

[BRG1200]

Father in law sounds like a handy chap!
Sorry to have to say the fuel tanks have always been the problem with these, you will very likely have to repair what you’ve got unless you’re very lucky to find a rare as rocking horse replacement.
The LC has a couple of good replacement ootions but no-one I’ve heard of makes a replacement for the RZ series.
What Jon suggests about the Indian “replacement” tanks, I’ve never heard anything but horror stories. Hand beaten from scrap by eye and don’t bear scrutiny and don’t even fit.
Mechanically RZ’s are robust and lots of parts still available, you may have to pay but you should find everything you need for the motor.
Rdlccrazy.co.uk is a good start for anything else.

[Jethro5]

Good to see a new post on the forum. Good luck with the build.

[Ozhammer]

Welcome casabonka (great forum name btw) and it is great to see another RZ being returned to use. It’s worth keeping an eye out on Gumtree and EBay, as tanks do come up occasionally, however, folks are these days all to aware of their rarity and value, so don’t expect a bargain sadly.

As has already been suggested, perhaps the most viable option would be to work with what you have, much as I will have to Dom with my own F2 tank.

[casabonka]

Does the LC tank fit these?

[Ozhammer]

No sadly not, the tanks are specific to each model (with the exception of the LC2 and F1 models I believe), which makes it something of a nightmare sourcing a replacement. Repro LC ones can be purchased out of the UK but I don’t believe anyone has started reproducing a correct copy of the power valve model tanks as yet.

[JonW]

LC2/F1/N1 are same, N2/F2 and LC are different.

Retro in Japan was making LC2/F1/N1 tanks.

[casabonka]

No sadly not, the tanks are specific to each model (with the exception of the LC2 and F1 models I believe), which makes it something of a nightmare sourcing a replacement. Repro LC ones can be purchased out of the UK but I don’t believe anyone has started reproducing a correct copy of the power valve model tanks as yet.

Bugger - was actually looking at getting one of these - https://japan.webike.net/products/22895030.html

[JonW]

Those are great tanks, I use them. They just dont fit your LC2.

[casabonka]

So back to step 1 with the tank.
Spoke to someone who specialises in vintage bike restoration and has just recently done a few of these tanks.

Rough estimate is between $1200-$1500 to finish in primer.
Is that what people would expect for a tank repair?

[JonW]

Tank repair all depends on what is required and I bet if this guy has done a bunch recently then he will know what hes looking at.

Looking at yours... Its hard to tell in your photos what yours needs, but i suspect its rotted out along the bottom edge on the side stand side. Usually on the outside from about 1-1.5inches up and then perhaps all the way along the bottom on the inside and outside of the crimped/welded seam.

To do this properly would involve cutting out the rot and letting in new metal. Tanks are thin as they are pressed steel over a former/die and as such welding is a bit of an art. Especially to not have the underside looking like a patchwork quilt of stitched on plates. You really want this butt welded in and hidden if possible. not always easy. Also does this work still need a liner or does he g'tee its fuel tight? Id want fuel tight and no liner for this money.

And... while the bottom is open, its a good time to bash up and out the dents on the top and sides from previous crashes. They will be some, these bikes have led a life...

All in all... $1200 sounds a lot but its pretty much all hours of labour. 12-15 hours at $100/hr I guess?

Ive no idea if its good value or not, you can buy another tank for less... but will it have the same issues? or develop them later? etc

Not easy this restoration lark...

[casabonka]

She's had a hard life, his quote allows for sandblasting, cutting the bottom out, removing all bronze that the previous person used, butt weld new section, pressure test, and prime.
For the hours needed, it's probably where it needs to be. Here is his page - looks like he does good work based on pics https://www.facebook.com/goldstarrepairs

Here are some close-ups of the tank;

[JonW]

That guy looks like he does amazing work.

This is Retro, you will struggle to get onto them as others have but maybe try ringing them, it will be under 1K i would think landed.

http://retro-spl.jp/publics/index/40/de ... lock215-24