Wednesday, April 29, 2009

Progress & Set-Backs



After retrieving my two RD400 "Donor-Cycles" I spent about a week just looking at them and dreaming. I scoured the Internet collecting data, downloading pictures and archiving technical data. "What shall I do? Streetfighter, Street-Tracker or Replica TZ Racer, that is the question!" After several days of deliberation and agonizing, I decide to build up both bikes.... The first project will be a "Streetfighter" and the second project will be a "Street-Tracker".


Step One - "The Tear-Down" I COMPLETELY disassemble one entire RD400 donor, bagging and tagging as I progress. A notebook is quickly filling with a long list of "needed parts". The frame, swingarm and various metal bits are sandblasted and then I start grinding off the unneeded bits from the frame. I paint, scrub, polish, and fabricate. I organize dozens of boxes filled with labeled baggies, each holding specific bits of the greater whole. The engine will wait patiently in the corner of the garage until I recover from my initial capital outlay.


Step Two - "My Stimulus Plan" I pull out the plastic and began my own version of the "Economic Stimulus Plan". By now I am on a first name basis with the guys at HVC Cycles, I have out-bid 80% of the RD-heads on eBay, and the UPS delivery man is asking questions - "Do you own some kind of motorcycle racing team?"! The parts are piling up in my study, garage, and living room.


Step Three - "The Build" This is "the big part" and I hope to have the first RD carving corners by the end of November 2009, just in time to freeze my leather-clad butt off. Progress is slow, mainly because I have a life outside of this project. My wife, daughter, extended family and work will not be neglected, so my timeline is a bit longer than optimal.


Setbacks..... So far I have not had any major setbacks or issues, just lots of frustration over the quality and execution of previous modifications to the bike. The worst issue is the wiring harness that has been sliced, diced and mangled by a series of poorly executed modifications. The brakes are also a bit of a challenge due to parts availability, or lack there of. I have already started making a custom wiring harness and I am scouring the Internet for brake parts.

Thursday, April 23, 2009

Inventory & Assessment


When I purchased the "donor-cycles" for this project, I got two partially assembled RD's, several large boxes full of "stuff", a motor with a connecting rod sticking through the case, a BIG pile of "miscellaneous parts", one well worn manual, and two clear titles to the frames. What a deal!


The seller even had one of the bikes running when I showed up! He started it up, rev'ed it a couple of times and then looked quite disappointed when I declined his offer of a test ride. No way was I riding that death-trap. After piling the heap of parts into my wife's garage space, I began sifting and sorting. I was actually amazed at how complete the parts selection turned out to be. With a little time on eBay and Craigslist, I could easily build two RD's from the vast assortment of parts littering my garage.


I sorted, I cleaned, I boxed up, and then I made a list of "needs" and "wants". Now I need to pull out the plastic and begin the "logistic & staging phase" of Project RD Racer.

Wednesday, April 22, 2009

The Wife (aka "The Gate-Keeper")


First let me say that my wife is an extraordinary individual, she is a loving wife and my best friend. She is everything that I have ever wanted and we have been happily married for 25 years. BUT....She hates motorcycles and totally disapproves of my "Two - Wheeled Fetish".


The trouble started when she returned home from a trip to her sister's and discovered a Suzuki GSXR750 in the garage. I had mentioned my thoughts of purchasing the Gixxer and she responded, "NO, motorcycles are too dangerous and you will get yourself killed!". I took her words as a challenge and purchased the Gixxer as soon as she left town. Within weeks of purchasing the GSXR my wife stumbled upon some of my Gixxer on-board video, documenting me carving up some twisty roads and exceeding 140mph on several straights. Yes, I know such behavior is illegal and irresponsible, but it is also thrilling and fun! When I get on the Gixxer it speaks to me like a devil possessing my sole, "I want to go faster, quicker, faster! Carve that corner! I need to see 10,0000 rpm, NOW!" The bike is "evil fast" and I survived the initial first year of "speed intoxication" before I regained my sanity. Now my wife just pretends that the Gixxer does not exist. "Motorcycle? What motorcycle?" She will not speak of it and shows absolutely no interest in it. Total denial! This said, you can imagine how she reacted when I drove up with a truck load of disassembled Yamaha RD's and then proceeded to deposit said pile in her garage space. Not a happy camper! The solution....... A brand new, high-end, washer and drier set, complete with a laundry room remodel! I built all new custom shelving for the laundry room, applied a new coat of paint and then installed the new appliances. She was happy and equilibrium had been restored to our state of marital bliss. Now I can begin "the build"!

Tuesday, April 21, 2009

Welcome to My Project


When I was in high school, the coolest road-bike to be had was the Yamaha RD400 or its earlier cousin, the RD350. These bikes were 400cc's of crackling two-stroke acceleration. Each weekend I watched RD's drag race and beat almost anything that fit into the category of "American Muscle Cars". I lusted over the little RD, but the little Yamaha smoker was out of my grasp. At the time I was consumed with motocross and most of my limited cash was dumped into my 125cc Honda Elsinore. Not to mention my parents, there was NO WAY they were ever going to let me get a streetbike.


Time flies and 35 years later I see an advetisment on Craigslist, "For Sale: Yamaha RD400 Basketcase Project". I made the call and about a week later I was returning home with what appeared to be the parts needed to assemble two trashed out RD400's stuffed into the bed of my truck. Just looking at the pile of rusted and greasy bits made my mouth water and my throttle hand tingle! Visions of yesteryear danced in my head, I was intoxicated with hope!


My RD journey had begun, "Project RD400 Racer" was a go!