Plan for restoration:
(1)
Engine & Drive-train: The engine needed a full rebuild. Since it is a 2 stroke single, a full rebuild basically means a rebore, a new crank and a clutch rebuild. Change the carburetor internals, seals, bearings, gaskets, fluids, plug, all disintegrated rubber parts (manifold, absorbers) and you are ready with an engine which will last you another 50,000 km. Oh, and also, replace clutch plates, springs, chain sprockets etc etc.- Done.
(2)
Chassis: Since the idea was to restore the bike as close to stock as possible, I was not planning to do any modifications. But since the bike was ill-maintained, most of the chassis components like front fork tubes and inner parts, rear shock absorbers, swing arm bushes needed replacement. Also, basic things like the centre stand and side stand were bent and had welds on them. Replace everything that needed replacement. - Done.
(3)
Body: I was not sure which colour to go for. As a purist, I wanted to retain the stock blue colour. But it is just too common. Everyone who rebuilds an RXZ (4 speed or 5 speed) blindly goes for the blue (God knows why, since the 4 speed Z came in 4 colours which I find even better looking). Z 5 speed came in blue and red - out of which the red is relatively rare. So out went the blue, in came the red. Since the panels, I had to source all new OE panels and getting the originals were a massive pain in the wrong places. Procured and painted - Done.
(4)
Accessories: If you noticed how I have decked up my RX135 and RD350, you know I like my accessories. But not just any accessories - only the OE ones. Oh boy - and only God and I know how hard it was to find a pair of original Alpha Toyo mirrors for the Z (took a full year!). Saree guard, crash guard, rear mud flap (ultra rare) - all took their own sweet time and lots of $$$ to come by. Yamaha did us Z lovers a big favour by making a thousand unique parts for the Z and then discontinuing their production almost overnight. My heart sank when I paid 250/- for two small rubber grommets! Yes Yamaha! Sigh!
Just to convey the pain of procuring the small unique parts for the restoration, I am just adding pictures of
a few examples of such parts!
2T oil funnel - used to pour 2T oil into the tank since it has a tilted entry hole from the side. Yamaha supplied it along with the tool kit.
Old MRP: 35/-, Current going rate: 350 - 1000/-
2T oil level switches - for lighting up the low oil warning indicator on the cluster.
Old MRP: 120/-, Current going rate: 500 - 1000/-
Headlight rain guard - fixed inside the headlight visor to make sure water doesn't run directly over the headlight and accumulate over it.
Old MRP: 80/-, Current going rate: 400 - 800/-
Brake lever rubber boot - a special boot was present on the front brake lever of RXZ 5 speed model (to cover up the master cylinder for the front disc set-up). A small piece of rubber, but it was very hard to find.
Old MRP: 110/-, Current going rate: 350 - 550/-
Front brake disc rotor
Old MRP: 1800/-, Current going rate: 10000/-
Front brake caliper
Old MRP: 2000/-, Current going rate: 7000/-
Front wheel hub
Old MRP: 1200/-, Current going rate: 3000/-
Rear mud flap
Old MRP: 30/-, Current going rate: 300/-
Tool box & lid
Old MRP: 300/-, Current going rate: 1100/-
Visor rubber beading
Old MRP: 35/-, Current going rate: 500/-