TZR sleeper project

[Nicesurprice]

The project and why.

First Englisch is not my first language, will try make as less mistakes and misspell's as possible.
Well in short, it's all about opportunities and being an idiot.
Son got 16 and started riding an TZR 50.
It ended with a full Polini assembly tuned by myself.
A bit a grey aria in the Netherlands, still a 50cc just too much horse.

The opportunity.

After he got 18 and having a driver's licence and no car, we kept the TZR.
Handy for the moments you got short off a car.
And now something started brewing.
Me having a motorbike licence as well, a light motorbike would be nice.

Only just.

Son needed transport and all cars occupied, his car needed a M.O.T.
So he took the TZR for a last drive to school.
Some farmer took the opportunity driving his Toyota Landcruiser into it so it became a financial total loss (the bike not the car).
Worse in first the plan was buying a 2005 frame with license and swap all parts and done project.
Now the frame was one off the few parts reuseable.

Being an idiot.

So building a light motorbike.
And starting from scratch.
Why wouldn't we upgrade the bike.
We do like a lot off "go".

So we googled the TZR line.
80 cc, mwa nope.
125 cc, better.
250 cc, nice, the best in line so why not.
I will be a TZR with a 250 cc engine.
With TZR-50 2011 appearance

The rules.

First my rules.

Need to be safe fully ensured and licenced.

Dutch rules.

Well there are 2 ways to walk the walk.
1.    get a bag off money swap the block, get another bag off money and get it licenced and it is street legal.
2.   Take small steps and use the system.

Well we don't have a bag off money don't ask for 2.

A cunning plan.

So we wanted the ultimate TZR sleeper.

In the past we did build some truck chassis so we know the system and how to use it.
All bikes 2005 and older just need a short inspection by the government @ the local RDW.
It's a safety check and they will check the details as weight, VIN and serial numbers parts and sound levels.
And they will conduct a short test drive.
Going from 50 to 250 cc could result in an expensive inspection with driving tests @ a circuit in Lelystad by the inspector and a whole new holomogation trajectory.
So we took the long and inexpensive road to success.

1.   Buy a donor 2005 TZR-50 with a license.

Iwanted to use the AM6 block in first so we bought an old 80cc cylinder and reuse the old 17.5mm Pollini carb (get a pass for the sound test).
And sell it to the inspector as a bored and stroked block 118 cc.
And we did swap all suspension parts and brakes.

Well it pass the tests and it's licenced as a 2005 TZR-125 now.
Whole suspension is FZR-400 rr we only changed the swingarm fitting the original shock.
With double Nissin's in front.

2.   Rebuild whole frame fitting a FZR400 rr pro-link suspention and new engine mounts.
      And go for the 250 registration.

So we wanted to drive it as the 80cc in first
We rebuild the AM6 clutch as a 5 plate assembly.
With TP friction plates and heavy springs.
Having the 250 registration we will respray or replace the body-parts.

Why a 3MA

Simple, having no room for a front Exhaust (or it would be a long ineffisient and ugly contraption).
The reverse cylinder option was the best for me.
Now we only need to redesign the cooling system (radiators) exhaust and air cleaner.

No sweat.
This was the introduction.
From here we will post the whole project.
And take notice we ain't in a hurry.
So step 2 witch started few weeks back will take some time.

[Nicesurprice]

The bike witch started the project.

TZR50 

Have no pics from the totalled bike.

The donor bike.

Donor

It looks nice.
It's a stalled project and a real piece off shit.
We only needed the frame wiring lume and body panels

[Nicesurprice]

Stripping the piece off sh*t and fitting some FZR-400 wheels.

The original contact fitted.

contactslot 

Temporarily shock assembly

14


Rolling assembly

24

[Nicesurprice]

Having lots off go, you will need a lot off ho.

36 

Rear brake.

32 

[Nicesurprice]

Well lets ride the b*ch.

39

Parts for part 1 back from powder coating.

alles in de coating

Bought some new black stuff

wieltjes 

Rear end still using the original chain.

achterbrug in opbouw

Rebuild calipers.

klaar voor nieuwe seals by Ronald Pellis, on Flickr

Naked bike.

black Beauty 

Dressed.

linker zijde

[Nicesurprice]

So we wanted to drive the bike as is while building the 250 with a salvaged frame without a licence.
We needed a better clutch.

The parts

Afbeelding van WhatsApp op 2023-09-04 om 15.37.29 

And the assembly.
We do have a Lathe so made a short exercise with the parts.

5 plaats

[Nicesurprice]

Lets go.

A gutted frame.

frame uitgebeend 

New upper shock mounts.
It's just a test fit after all done we will finisch the mounts.
And the frame is an scrapp frame.

Proefpassing boven aanzicht 

Side view.

Proefpassing zij aanzicht 

[Nicesurprice]

Using a FZR-400 swing arm we need FZR-400 gear's
Using math we discovered the gear ration TZR and the FZR are almost the same.
The difference will be found few digit's behind the dot.

fzer sprocket 

And the splines did fit as well.
We only need to remove some material from the body.

Found a cover.

sprocket with cover. 

[Nicesurprice]

On a Dutch forum we found a tested design exhaust.

Demper 

And with benefit's .
It will fit more easily.
And second we would have few more horse.

The only issue.
We will need new upper shock mounts.
The bracing will be used again.

Back to the drawing table.

And this is the status for today.
We have drawn new mounts.
Will have to throw them on the stack off word for plasma cutting.

The exhaust will be build when the engine is placed complete with cylinders' and power-valves.

[ybk]

Very interesting So a 3ma engine a 50 chassis, this will be a quite a riding experience. A sleeper indeed..

[Nicesurprice]

Indeed.
And for the suspention.
It all fit out off the box.

Only for the pro-link we need to be creative.

We drive it in the original rear spring set-up now.
And the only negative it bottoming-out in the rear, thats why we will change to pro-link now.
Drive's realy good, all rubber bushings are gone all needle bearings now.

For more stiffness we will create somekind off a triangle with upper enginemounts and with the lower engine mounts the engineblock will brace the lower frame aswell.

So no flex and for the rest use youre brain.
The build is all about a fun machine riding the country roads.
It will never be an touringbike.

[Mad Jack]

Will that exhaust work on a TZR250 2xt? Can you please send me a link to the dutch site where you got the exhaust design from? Thank you

[Nicesurprice]

Will that exhaust work on a TZR250 2xt? Can you please send me a link to the dutch site where you got the exhaust design from? Thank you

shore we can.

https://ytcn.nl/e107_plugins/forum/forum_viewtopic.php?id=234

Do not know it will work as is.
Maybe it need some tweeking.
on the site you will find drawings for the exaust.
If you like i will provde the DFX files for laser cutting.
so it would be a bend and welding project.

greets Ronald

[41juergen]

You also can use Louis website directly:

http://www.tzr3ma.com/index.html