Mission: SAVE the TZR! 2 Stroke Rebuild – Part 8

It is time to be positive and put some effort into saving my TZR. After a head on crash that was so slow it didn’t even break the headlight it turns out not only the forks and wheel got bent but the frame too!

My mission is to get this motorcycle back on the road in time for summer. It’s been a huge journey so far and although this crash has put me back to before square one, I’m going to try!

Full Playlist https://www.youtube.com/playlist?list=PLZS-FDeuf2R3ENz2aWMUTko9niMdZlXA4

00:00 Introduction
02:00 Garage Dehumidifier & COLD
03:28 Fairing & Headlight Removal
04:40 New tools for the garage
05:55 Fuel Tank Removal
08:52 TZR Exhaust Removal
14:51 Removing the Airboxes
18:48 Removing the TZR Radiator
25:07 Front Calipers and Brakes Removal
28:35 Plans & TZR 3XV Throttle cable
30:35 Conclusions

So with the zip ties just going to thread one around the end of this spring and you can use a screwdriver or whatever you want I might as well use this as this is a new thing I’ve got and then just pull that comes off real Easy hello everybody Welcome to my garage and look my Christmas presents from my eldest son from my youngest son um and we’re going to start to use this now because I need to fix my tzr um reason why I need to fix it now in the depths of winter is that the uh

Maidstone motor liner the place that straightens frames they’re not overly busy right now because not a lot of uh recreational Riders those are the ones that crash the most are riding around at the moment uh there’s not a lot of motorcycle racing on in the tracks

Around the UK so they’ve got loads and loads of Jigs and things for fixing bent motorcycles uh and they’re not using it that much so we need to get teas ITR stripped uh so we can start getting that sent off to meso motor liner so let’s get this

Out in terms what needs to come off this bike um basically they’re going to heat up the front end and reset the uh the the for reset the headstock so I need to get all of the cooling off all of the wires all of the plastic um all the carbs everything off

So when they put it on their jig and heat it up to super hot temperatures it’s not going to cause any damage to anything else so it’s a little bit chilly in here I’m going to get my um boiler suit on uh at the moment it’s about 7°

C uh but the humidity is only 52% um even though the humidity is uh 70% outside reason for that is I’ve got a dehumidifier come and have a look at this so here is my dehumidifier and this is running 24/7 uh I had to amend the shelving for

It to fit but this is costing me about 2 p per day to run um obviously today it’s probably be costing a lot more but over the stretch of a year it’s round about 2 p uh to run uh it’s not a compressor dehumidifier which is better for colder

Temperatures so it works in the garage so that’s going to keep the DEH humidity that’s going to keep the humidity down um but it’s not going to keep me warm so I’m going to get my uh boiler suit on I’ll get this shroud off uh with the

Headlight then the tank then this stay then we’ll look at getting the brakes off trying to get these clipons removed and then something to uh capture the coolant in for the radiator get that off airboxes off exhaust off let’s just see how we get on um I’ve taken some of

These parts off before some of these parts I haven’t so uh let’s get on with it okay okay okay so this um is going to be fairly straightforward to get off because I didn’t really put it on that tight this was just test fitting there only two bolts that hold this on

Okay so what I’ll do is I’ll put bolts back where I found them I’m not a great fan of uh you know putting everything in a plastic bag and like labeling it tzr or something I I need to be a lot more organiz than that

Because I’m just not going to be able to put this thing back together again so that’s the challenge and the whole where the tzr used to go is now going to be a hole where the teasel parts are going to go and I normally use uh an 8 mil socket

To take my tank off but these are ratchet uh spanners that my son got me uh so we’re going to just try those and let see what they do so there’s the uh the 8 mil there um also because I’m taking the carbs off I’ve bought myself some uh Japanese industry standard

Screws screwdrivers rather because all of the screws in a carburetor are JIS tools they’re always all hacked to Pieces cuz people just use Phillips on them including me so I thought I’d get the right ones the next thing I’ve got myself is some tea handles just because it’s a bit more

Convenient than using my ratchet and the um and the alen bars right let’s give this little tool a go let’s get this more into the light here’s uh here’s the ratchet spanner um let’s we go okay I see see how this works so one side will tighten the other side will

Loosen that’s quite handy um before I get this uh tank off completely I need to find my special Yamaha tool right the special Yamaha part I’m talking about is of course this um you can get that in any wood store basically just enables me to to prop up

The tank so you can get hand in take off the Breather oh this is fiddly there you go take it off the fuel this is a RGV petcock so it’s not standard uh Yamaha one the Yamaha ones always use the uh the vacuum petcocks uh I’ve never really got on

With those I did have a vacuum one used a rebuild kit on it and it’s still uh it’s still leaked so the RGV one just fit so use that and on to the tzr parts bin another one of my new toys one of these um uh T handle hex’s um if you look

Closely it’s got a uh a ball end on that which means it doesn’t have to be 100% perpendicular this is going to be really good when it comes to adjusting the chain on my um ducatti Multistrada because if you can use a b end then you can adjust the chain without taking more

Bits off but anyway this is the bit I’m need to get off now so just take that rubber thing off so you get more leverage if you use it that way then you can spin things out there you go that’s quite good happy with that just add I am no expert I’m just

Doing this because not because I want to do motorcycle mechanics but because I want my tzr working again and I can’t afford for somebody else to do this for me okay excellent on to the tzr parts spin with this so next thing to do is get the exhaust off

Somebody clearly didn’t want these to fall off while I was riding and that’ be me now before I take this off completely I’m going to take a note of how this is all lined up and just grab a little piece of cardboard so I can effectively build a template so I

Know which side the exhaust goes which side the bolt goes and things like that so I use this to represent the frame basically so I know bolt goes through the frame into that and then there’s a washer that’s fell off which I’ll collect and then that goes on the back

Right now let’s get the front off which are these um really really strong brand new Springs and there’s a little trick that I use to do this so with the zip ties just going to thread one around the end of this spring and you can use a screwdriver or

Whatever you want I might as well use this as this is a new thing I’ve got and then just pull that comes off real easy so this will be easier to get from the other side I think okay and that that is not going to be long enough

To get from the other side which will give me a straight pull so what I do is just put another one on you can see what a really awkward space that is to get in but if I just put another cable tie on then I could drop that down the other

Side so now on this side I’ve got a fairly straight pull on it there you go that’s off the exhaust all right so let’s reassemble that’s the bit where the frame goes then I just like just Loosely put that back go right let’s get these Springs off first

These are on the front it’s a lot easier to do here and you’ll probably be able to see what I’m doing as well so in cable tie Loop it behind the spring make sure it’s engaged grab like this or a screwdriver or spanner or whatever you want there

You go comes off nice and easy the other one there you go nothing got injured no peoples no parts all good right okay hello let’s get this uh this off oh that might be the wrong way around okay so that’s loose I just loosen it from from the front and another exhaust

Out okay so we’ll just pop this all back together again like we remembered it nothing in it the reason why it was so hard to get out was because what I use here um is flu sealant um and that gives a really good seal okay so next thing to do is get the

Airboxes off let’s do do that I don’t know how much I need to remove off this bike before Maidstone can put it in there in their heat jig I’m just going to have to take some take a lot off and then say to them is this enough or do you want me

To take more off cuz I really don’t know and for example there is a uh a plastic gear for the oil pump that’s on uh the right hand case and you can’t take that off unless you take the right hand case off so do I

Need to take that off I don’t know so let’s get that out of the way leave that in situe now good test for my JIS screwdrivers because again these are all the ones that get niled up by people using Phillips so what does this say JIS Phillips

One let’s try the two I think that’s probably going to be more more like it get this screw off here wow that fits so well that fits really well so nothing spinning or getting in the way it’s brilliant right bolt up here I’ve forgotten keep all these screws in

Place and then off to the parts spin okay I think I’ll get this boot off as well now I have the right screwdriver for this it just feels so much better taking this stuff off than it used to do hope hopefully the threads oh the heads aren’t too

Mangled but that’s the top uh boot okay that’s that off and then deep in here there’s and the clutch cable gets right in the way but it’s in there my new ji screwdriver this is a dole that top snorkel comes out let’s get this uh front boot

Off okay so that got that off now and just a couple of 10 ms and then this is off as I’m doing this I’m looking around the bike for anything that looks plastic and meltable um so obviously this needs to come off the coil needs to come off and then obviously every every

Wireing tube needs to come off I think that’s it yeah that’s it you just got to wriggle this out because there’s that thing on the end there you go so that’s the lower carb off um obviously there’s the main oil pipe that on the to come off um we’re taking the carbs off

In a second um and the oil pump this obviously is just plastic just covers the dry clutch that can come off that’s not a problem we’re taking all of the coolant off so that’s no problem and we want so I’ll take this boot off as well because that

Goes with that right so got to get the coolant out again last time I thought I had a really great idea uh involving a plastic bag a funnel two Chopsticks and a hamster bow but it went everywhere so this time I’m just going to drain it

Into this tub and then we can sort it out later that doesn’t look great in there does it all those bits I don’t think I’ll be reusing this coolant magnet on a stick which I use for collecting things that I’ve lost no that is not magnetic do you know

What that’s probably the last time I tried to save a load of coolant and introduce some grit so let’s not use that let’s just try it action all right so let’s get this tube off okay so that’s one rad hose off and we’ll go and get the other side

Off and then we can get the radiator out just loosen this up it will come off when we wiggle the radiator out of position and let’s get this radiator cap can come off we don’t need that anymore and the Breather that can come off too and so it’s just a matter of now

Three bolts and I can take this off so there’s two bolts on this side one is this lower one here which holds the coil on and that should enable that there so that swings loose oh that’s a good idea there’ll be some spillages you’re just going to have to accept it um and

Then this top one here you’ll notice that there’s electrical connector there that’s an earth that I’ve used for the Zeal which it’s not a standard uh connector but I thought it was handy so I I just reused it even though I’m not putting the bolts in a template I’m just putting them on

The floor roughly where I got them from okay there that one and then one on the other side and if you remember the videos this is the side that I repaired because this was all smashed up and so I drilled and tapped it the reason I’m not worried about this

Flopping on the floor is I know this is on so incredibly tight it’s really awkward to get off okay there’s that one let’s take these are away cuz they will just rattle around and noce so there’s nothing uh holding that that on that side uh we got this tube here which

We might be able to wrestle off in a minute the fun bit is getting the radiator over this uh stud here but it is actually a stud so what we’re going to do is we’re just going to remove the stud completely in order to get this stud out you just

Have a couple of uh 10 mil nuts wind them on a little bit and then if you lock them together like you do uh for a chain adjuster then you can unscrew as if this was a bolt so let me grab another 10 mil spanner and just nip them

Together there you go and that comes out and that’s a lot less hassle than trying to bend it and prize it and taking the cooling system off a tear is a real pain but once you know that trick about the stud it’s an awful lot

Easier so let’s tip the rest of that in there this went in from that end I’ll leave these uh bolts on because I’ll use those to uh tie it down just grab all the bolts put them where they were and then it’s off to the parts bin with

You okay so I think the next thing I’m most comfortable with is getting the brakes off because I’ve done that before so crack on make a start with that if I get the calipers loose first so the idea is you just take the calipers off um disconnect everything

All the way up take this brake light switch off and then effectively just lift the calipers the hoses and the cable completely out as one unit and these weren’t on very tight which which makes me wonder um have I been messing with this before oh yes

That’s right I bent the front end and I’ve just put these on to test fit them so oh well probably the only thing I did do uptight just paranoid about losing the speedo cable right that’s the speedo cable let’s get that there cuz then that can come out here okay that’s one

Off the other side and get the other one off okay that’s the other one off and then if we undo from the top here doing this in half an effort to uh be lazy which is bound to cause me problems later my idea is that I just take it off

As one complete unit and then I don’t have to worry about bleeding the brakes or anything like that we’ll see what happens that there you go potentially easier than I thought so I need to find somewhere to hang this up right um that’s left me with my Speedo cable

Which I’ll put in the parts Spin and I probably shouldn’t say that this is the recommended retail route for storing your brakes but in my defense everything is the right way up and nothing’s stressed so let’s put this in the parts spin right ah okay yeah they’re over

There um so now we’re going to get into some really really tricky places uh the electrics okay we can start labeling these things so we know where they go um but this is got to be the most complicated throttle cable in your life come over here let me show you right so

Throttle cable starts up here it then goes into this box in here where it gets split into uh three so one goes off to the the carb on the right one goes off to the carb on the left the other cable goes into this box

Here now this box one cable goes up here into the power valves and the other goes into the oil pump so this horrendous ball of snot has to come out because if this area is being heated up is going to get destroyed other things that need to come out obviously all the

Electrics the variable air Jets need to come out um basically the clip-ons need to come off as well but hopefully that won’t be too much trouble apart from the clutch cable uh the clutch cable goes down here into behind the engine and it’s easiest to fit this with the engine out the frame

So I really don’t want to have to do that hopefully I’ll just be able to get away with pulling this through and then uh tying it to the back of the bike hopefully that’ll be enough um obviously there’s a lot to go on here so

I’m not going to get it done right now okay I’ll leave it at that I’ll have a think about it especially about how I’m going to get all these electrics out um and these cables out uh I’m moving now into an area where I haven’t done anything like

This on this bike I mean this is once again this bike has forced me to to learn things that I didn’t even want to learn and now I’ve got to learn how to deal with the electrics and with the uh with the throttle cable so yeah let’s

Leave it at that I’ll come back to this next weekend and um hopefully get it ready to send off to M motor liner okay take care bye