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My classic Yamaha RZ350 restoration: How I got the fuel tank repaired

11th October 2024, 16:36 by Dev Shah

Top paint was scraped off to expose the welding work done which was hidden under the paint.

BHPian SnS_12 recently shared this with other enthusiasts:

As an update on the RZ tank the welder has almost completed his work and more than 70% of the original metal has been replaced as most of the patch work done earlier had gone bad. The guy first opened the entire bottom portion of the tank which cleared the biggest doubt that we had that is if the petrol filler cap is the original one. The previous owner was confident and mentioned that its how it came on the JDM version but I had my doubts as during my research I never came across a single RZ with this type of a tank fuel fuel cap setup. Hence a decision had to be made whether to change it or not. I wanted to retain the original shape and look but then I needed the bottom portion of the original tank to we welded back on. Since, that would only be possible from a scrap tank outside of India the next best alternate was a bullet tank cap and we got one from the local shop along with the bottom tank metal on which the cap screws on.

Now, the tank will be fitted on the bike to check if all clearances and alignment is proper with the side panels and seat along with the fuel cock alignment and after this is done the tank will be sent for the internal epoxy coating. This tank would be kept as a backup as I will mostly go with the new replacement tank which is going to be a challenge to carry back from UK considering its size and the other parts I have to carry back along in my next trip whenever that happens.

Some pictures…

The whole old bottom was cut out to be replaced

Surprise Surprise

I hope whoever did this didn’t do it to fit this type of fuel cap as this piece has been fitted with the water drain pipe required for this setup which had choked up and had to be replaced anyway.

The old rust was scraped off

Top paint was scraped off to expose the welding work done which was hidden under the paint

The big patch that was welded on

RE to the rescue of the RZ

Bottom part of the RE cap

Time to replace it with the new cap metal bottom

Old piece if finally off. Hopefully it will now take on more fuel because of the filler cap placement which means lesser fuel stops

The new piece is not welded on yet and the final positioning is being checked.

You can see weld marks on the bottom section around the edges of the tank which was replaced as well.

New bottom has been finally welded on the tank

Side angle

The other side and you see the weld mark from where the new section was welded on

Top view of the nearly finished product.

The amount of parts that have arrived at my friends place in UK which I have to carry back on my next visit

For a change decided to take the RX for a longish Sunday breakfast ride

My dad rides the RX more than me and since he rides it very slow a lot of 2t oil gets accumulated in the crankcase which get cleared when I ride it the way its been built to be ridden which is like a hooligan. Also, I wanted to run in the new tryes and check the feedback from the tapered bearing cone set replacement. Surprisingly my dad took it a day before fir some work and he commented that it rides and feels so good. To get such a compliment from him wasn’t expected but I am sure we will still have our disagreements on the amount I spend in maintaining my bikes to keep them running in top shape always.

ABCG juice for some detox

Followed by some nice strong coffee

And then by some good Parsi Akuri. It was my first time at this place and I loved it

An Iconic image with my first bike and what could/would be my first car. I keep telling my family if you think my craze for motorcycles is what madness truly looks like then just wait till I start buying cars

Old is gold and sometimes also pink

Karfule Pump is my new favourite spot to take pictures

Barn find. My dad mentioned to me that the garage which has been closed (haven’t seen its inside contents since 1997) for decades finally revealed its contents as the roof collapsed because of its age and this it what greeted the society members who had forgotten that something was parked inside who knows when. Its owned by an old Maharashtrian gentleman who stays in the same complex.

Seems to be like an old Austin but the rust is so bad that I couldn’t identify any markings to confirm it. The car is as long and wide as the garage without even the body on it. Trying to connect with the owner to get the history/story behind it which I am sure will be an interesting one.