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Re: RZ250 Rebuild!
Posted: Fri Feb 10, 2023 9:47 am
by JonW
Hmm, with no spark i think its something fundamental. I'd advise you follow the wiring diagrams and check the power runs as expected, across the switches and through all the connectors. ie check continuity for the +12v and also check the whole kill switch circuit isnt earthed.
Also make sure youve plugged all the loose wires around the bike in correctly. Maybe youve earthed something that shouldnt in the ignition system etc?
Re: RZ250 Rebuild!
Posted: Sat Mar 11, 2023 8:40 pm
by casabonka
Some good news!
Ordered a replacement (brand new aftermarket CDI) after discovering the replacement I purchased earlier was also dead and she lives!
Blue slip hopefully this week and then time to get her on the road!
Re: RZ250 Rebuild!
Posted: Sat Mar 11, 2023 11:01 pm
by JonW
great news!
Re: RZ250 Rebuild!
Posted: Thu Mar 16, 2023 10:42 pm
by Ozhammer
Great work, glad this didn’t end up with you chasing your tail
Re: RZ250 Rebuild!
Posted: Mon Mar 20, 2023 6:27 pm
by casabonka
We're on the home stretch!
Blue slip sorted, and now just need to get to the RTA to register her and pick up the plates. Bring on the weekend for a ride and some more photos then

Re: RZ250 Rebuild!
Posted: Sat Mar 25, 2023 8:57 pm
by casabonka
And she’s home!
4 years and 2 months since purchase it’s all done!
Bought her home this morning, did a couple of laps around the block after the rain and spent the arvo/evening giving her a proper detail and ceramic coat.
Beyond stoked with the final result!

Re: RZ250 Rebuild!
Posted: Sun Mar 26, 2023 10:59 am
by JonW
very nice, great to have another one back on the road! Enjoy!
Re: RZ250 Rebuild!
Posted: Wed Mar 29, 2023 11:29 pm
by Ozhammer
Well done, that is a credit and love the plate too! Hope she gives you get many many kms of enjoyment from her.
Re: RZ250 Rebuild!
Posted: Tue Jan 28, 2025 9:30 pm
by casabonka
Hi everyone, long time no speak/updates!
Bit of an interesting one over the weekend where the front calipers seized, whilst cruising along at 90km/hr. Luckily I could feel early on that it was labouring so I pulled over fairly quickly with no dramas.
Long story short, after getting it towed home and releasing the calipers, I ended up with now no front brakes. I have bled them a few times with no visible air, pads are still almost as new and lines replaced when I did the restoration.
Master cylinder seems to be working, but not sure it is faulty or if there would be something else I need to look at?
Thanks in advance!
Re: RZ250 Rebuild!
Posted: Thu Jan 30, 2025 2:17 pm
by casabonka
Turns out I hadn’t bled it correctly, so appears ok for now!
Re: RZ250 Rebuild!
Posted: Fri Feb 21, 2025 6:10 pm
by James W.
[Great work on the RZ 250 resto!
Good effort to problem solve those brakes - I had the same issue with the very similar single-piston caliper front brakes on my RD350LC - I never did get them to have much 'feed-back' sensitivity/feel & so I replaced them with the same type as on your bike, to not much improvement, still had that 'wooden' feel (though I have ridden with some that did work way better, of the same kind). I always wondered why the 1st gen RZ had a better 2-piston caliper on the back brake, but stayed with the sliding/single piston jobs up front - right up to the `85 do-over.
I eventually put a set of those 2-piston units on my RD, (used with an adapter-plate), & did fit the wheel-width, ok.