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Sprockets and chain both need to be 520. You could get a fusebox that takes spade fuses as those fuses are more common these days. Inline fuse holders would also do the trick, but be less "clean" than a box.

Have to say I quite like the lightweight motor. I did move bit too fast with this though as I don’t have flywheel holder, so pulling the flywheel might have to wait for the holder to arrive. I used always reliable tie down strap method to pull the clutch basket, and should have done the same on...

Looks awesome. I don't know how I've managed to miss this.

You're probably right about having to split the cases. Did you try using the kick starter to turn the motor over once you had the motor put back together?

That looks pretty good to me. Check compression, take a peek under the cylinder head cover and if OK, adjust tappets and ignition and see if you can get it to run.

Thanks guys for excellent info. Looks like I'll try one of those DIY leak down testers. Have 0-15 psi gauge already, so cost shouldn't kill me. Filling the cases with diesel fuel doesn't sound like something I want to try.

Would one of those cheap chinese $100 testers work reliably enough if I connect it to one spark plug hole and plug everything else? It feels like I’m throwing fist fulls of $100 bills at various things right now and don’t really want to spend much more on anything. How about the ”nature” of...

So, I listened to somebody, who claimed that you can replace the crank seals with the engine in the frame. That seems bit sketchy, as applying any treebond to seal the cases seems pretty darn tricky if the engine is in the frame, and new seals would do F-all if the cases would leak. Now I'm...

I had an error in the pilot jet sizes in the above post. I edited the original post so there's no info there. I did order the jets based on the correct info. I took the covers off yesterday to get to the crank seals. Looks like the clutch plates and springs are not OEM, so I'll assume they're...

I found some jetting advice. Powerjets are apparently 60 and 65, so to get to same as regular carb 240-250 main jet, I would need to up my main jet to 185-190. I was also adviced to use 27.5 pilot or bigger. So my thinking right now is that I should probably get 185 and 190 main jets and 30 and...

Jetting question. Since the bike has Mikuni Power Jet carbs, I have hard time finding info on jetting as the jetting is different from regular Mikuni and jetting information is hard to find. Currently the bike has 160 main and 27.5 pilots. Stock airbox and DG pipes. I intend to ride the bike on...

Things have improved, I should have the consumables etc. this week, so I can proceed with working on the RZ. Don't want to start tearing it open before I have all the seals and gaskets to put it back together. It's also warm(er) so I can work in the garage. Took my KTM for a nice 2 hour trail...

Right now I'm washing all the dishes for the second time, baking sour dough bread, vacuuming just in case, and doing home schooling tasks with the kids. Reason for this is that I've ordered all my "consumables" for both of my bikes and the cost is what it is. I would also like to pay this...

So now we know the bike runs. I called the previous owner today, as he is bit of a walking motorcycle encyclopedia and all the shop manuals put together. Or at least he is the most knowledgeable motorcycle guy I personally know, and under normal circumstances, I would be getting the info at out...

Well, this is bit embarassing, and hasn’t happened before (yes it has), but I didn’t prime the empty carbs and that’s why she didn’t want to start. A whole lot of assing around in a cold garage for something similar to ”do you have it plugged in?”

The carbs are not stock, but I found out the line is for petcock vacuum. I’m freezing my ass in my uninsulated garage. I thought I had the carbs setup the right way, but it doesn’t look like it. The bike runs 1-2 seconds when I squirt 10-20ml of fuel in the cylinder and kick it over. Just...

Carbs cleaned, and I'm kicking myself for not getting ultrasound cleaner before. I'm also kicking myself for not taking pictures of what I took off the bike as I have a brass fitting on the right carb, that has a line running from it, but I don't know where the darn line needs to go. The brass...

How is that master cylinder? I was eyeing one on ebay as it looks good, but does it seem to work well, is it solid?

Opened the carbs for cleaning, bit nasty I’d say, and now the garage stinks. Need to give them an ultrasonic bath.

Nevermind about the nose cowl, it's supposedly the same piece on RD/RZ500, RZ350 and RZV500. @3DogNate 2 strokers tend to sell fast, or at least every single one I've ever spotted.