Building a TZR250 Track bike

[Mick]

After thrashing my road TZR250 1Kt around Cadwell Park i got bitten by the track day bug and decided to buy a bike just for track days and this came up on Ebay in UK which i bought for £160

It had a TZR125 4DL rear swingarm fitted which seems to drop straight into a 2MA frame

FZR400 front end fitted but it didn't come with calipers i won a set plus hoses and master cylinder for £25 on Ebay

The rear wheel fitted is a 17x 4.5

Which presents a small problem as the spindle is 18mm as apposed to 15mm on standard 4DL.I could machine the caliper carrier and chain adjusters out to 18mm but i'm not sure at minute whether rim with obstruct chain run.I will fit engine,rear sprocket and check before i machine parts.

The cush drive has,so seller claims,has been machined so chain run will be ok but saying it will work is completely different to actually testing it..The tyre in rear wheel is a 150mm.I know you can fit 150mm on a brembo 3.5 rim and it will go straight into a TZR250  with minimal clearance between chain and tyre.

It's been time consuming aquiring 4DL parts but luckily a broken one came up on Ebay,so suspension,brake and chain adjuster parets all bought I already have two spare 2MA engines(which need rebuilds),Fairings i already have apart from a race seat unit but POLY26 do one,footrests,PV servo motor,CDi,Radiator,tank support,engine cradle and stator all purchased.I'm going to make my own wiring loom as TZR looms are hard to come by and anyway looking forward to making my own loom ..The hardest part to come across was the "dog Bone" engine mount that runs under left hand side of engine lucky for me a Guy from Latvia advertised one on UK ebay.I need the nose fairing support bracket,there are a few on Ebay but well expensive,I have time on my side so in no rush atm.


Most parts I now have but unfortunately i had to have a Carpal Tunnel Op on Saturday(10/11/2012) so progress will be bit slow until new year but guess it means i can get dremel out and clean up parts..

[tzr-v4]

Looks like the front end and the rear wheel comes from an FZR400R 4DX or 3TJ bike.
I'm working on a front end swap too.
http://rd500lc.free.fr/tzr-250-2xt/tzr250-2xt_en.htm#14
Need new steering bearing and master cylinder to complete (and cash too)...
Maybe 2013

[Mick]

Hi Oliver the front end is defo early version has later calipers won't fit,don't line up "eye to eye" with fork mounts..
Yup i thought rear wheel came from 3TJ,i have a 3TJ rear end in my FZR600 and they have those unsual tapered chain adjusters too..
Carbs seem to go for stupid money here on Ebay,while at the Yamaha RD Aircooled rally this year one guy had a set of OKO 28mm flat slide carbs on his 350.I think they are a copy of PWK28's that are fitted to KR1S,they get good reviews on the scooter(lambretta)forums in UK and cheap.
http://www.ebay.co.uk/itm/OKO-28mm-RACING-CARB-FLAT-SLIDE-CARBURETTOR-/280792532968

[tzr-v4]

FZR400 front caliper mount is 84mm not 100mm like most FZR600-1000...
You have an FZR400 3TJ fork with FZR400 1WG on.

FZR400R 3TJ rear wheel is 17" not 18" as 1WG or FZR600 3HE ones.

Yes OKO carb are OK but you may need to put Keihin MJ SJ...
I've manage to buy from Kawasaki KR150 rebuilt kits but not tested yet !!!
Not from this seller but similar
http://www.ebay.co.uk/itm/CARBURETOR-CARB-REBUILD-KIT-PILOT-MAIN-NEEDLE-JET-GASKET-KAWASAKI-KX85-01-02-07-/200825377012?pt=Motorcycles_Parts_Accessories&hash=item2ec22010f4

Maybe a good deal if shipping is OK
http://www.ebay.co.uk/itm/NEW-Keihin-PWK-carburetor-main-jet-kit-repair-kit-/160685395145?pt=Motorcycles_Parts_Accessories&hash=item2569988cc9

My repair kit :

[motomaniac]

its looking good! i ammaking a similar project. the linkage for the rear shock seems to be the 4dl.  waiting news from you!