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My Yamaha RZ 350 and RD 250 Daytona Special: Restoration story

8th October 2024, 13:33 by Kanad Kalasur

I came across something interesting which only the Factory records will be able to answer as too why they did this modification on such a limited production run motorcycle

BHPian SnS_12 recently shared this with other enthusiasts:

As I had mentioned earlier I had ordered the wrong size front and rear brake internals and while I have to wait to carry back the right size parts from UK my friend went through his parts bin to see if a temporary alternate could be done so that the motorcycle becomes usable and as luck was on our side he did find a front mast cylinder unit without the lever and the part I had initially ordered as a replacement was a perfect fit on this master cylinder unit. This is a temporary fix till I get the right part back to India as I am going all out to maintain the OE parts and originality on both the Daytona and RZ. The rear master cylinder is currently running a R15 internal kit which is slightly smaller in diameter but working as desired. Initially there was a leak around the master cylinder but it was due to a damaged pipe which connects the oil reservoir and the master cylinder. Now the bike is 100% sorted mechanically except for the 2T pump which has to be drained out with new oil and adjusted for factory setting.

Further, while continuing with my ongoing research on the Daytona I came across something interesting which only the Factory records will be able to answer as too why they did this modification on such a limited production run motorcycle. I wanted to get a spare tank and had identified a few used one including a new old unused tank. I was just comparing them and while visually they would look similar including the decals most of the tanks were designed for the RD 400 Daytona Special and were unlike the one on my 250 Daytona Special. The 250 tank is wider and resembles more to the TZ 750 tank (Coffin style) especially when viewed from top. Luckily I could identify this difference or else I would have ended up with another part to be kept in storage for ever and this would have been a very expensive display piece only

Coming to tanks on inspecting the RZ tank we found out that it had been repaired from the bottom in the past and there was a leak and the water drain pipe was clogged as well. These tanks are known to rust and given its age I was prepared for it and expected nothing less. Luckily when the Daytona tank was given for a internal epoxy protection coating the painter told us about a guy who specialises in repairing tanks and we have given him the chance to try and fix it to the best of his abilities. While the whole bottom part of the tank will be replaced with a new customised piece, all the mounting points will be retained from the older piece for a perfect factory fit. However, I don’t plan to use this tank as I have ordered a UK manufactured copy tank that is supposed to be off good quality. With years of rust I didn’t want to end up in a situation like my RD 125 where the paint starts bubbling up.

Sharing some pictures on the above update and of parts that I have ordered further for the RX, RD and RZ…

Stocking old good parts always come in handy

Luckily the wrong 5/8” diameter internal was a perfect fit. So incase of any issues in the future we have a workable backup solution

The difference in diameter. Looks like most of the frame parts and brake parts are from RD 400 Daytona Special

Ordering this kit as well so that new internal rubbers can be used for the original kit which have now worn out due to age and use. Kit is similar for the 250 and 400 Daytona series.

But closer inspection of the tank says otherwise. Mine is on the right and on the left is a old new unused piece available on Ebay demanding a price tag of a few body organs. Same same but different. Mine doesn’t match any of the RD series and I will definitely have to get one made basis the original design as a backup. The Factory guys were really crazy to do something like this on such a single number exclusive limited edition production run.

I compared it with a used tank available on Ebay to confirm my findings and the 400 DS tank both used and new version have identical design which don’t match the 250 DS design

Top view comparison. Mine on the right is wider and looks closer to the coffin tank design seen on the legendary TZ 750’s. Factory team was like while everyone is focusing on four strokes we will end the air cooled two stroke run with a bang. What a homage if that is what the designers intended to do with this motorcycle.

Top view comparison with the new and used 400 DS tanks.

Attention to every single detail. Can you spot the difference?

Patch work done on the RZ tank

The slow leak

The UK make copy tank. Supposed to be off good quality and not like the ones made in India and sold on Ebay for a premium.

The filler cap position like the regular RZ/RD LC series. The seller also got me a matching key fuel cap, ignition key to match the seat locks I got from him earlier. So a single key will do the job.

The JDM version OE tank will be fixed and kept as a backup for the next 45 years

Decal Set for the JDM version just like mine. However, Sumant from OCD Detail Studio is confident that we can replicate the decal in paint.

OE design three piece front brake pipes. Current ones are braided as well but is a two piece connected directly to the master cylinder.

OE design non drilled brake rotors for the RZ

Wiring harness for the RZ. Not sure if I would use it but being ready if we need it.

Tapered cone set bearings. I had ordered two from WeBike, Japan but unlike Yambits they don’t stock and based on order ask their suppliers to manufacture. Since, they were not able to give me a shipment date even after a week after placing the order I cancelled the whole order and got these along with other parts from Ebay UK. Cost wise they were cheaper too and plus no shipping and customs.