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Thread: 1986 Z50R Rebuild

  1. #1
    Forum Founder Classic Honda 50's's Avatar
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    1986 Z50R Rebuild

    I purchased this 86 Z50R back in the early 90's, at the time I had the Monkey fever really bad and was buying any and every Z50R I could find, this one come from the Central Coast in NSW and was an incomplete roller with a box full of engine and other parts, I still remember that Nichole did not get out the car that day and was not very happy to see a bike take several trips to get it all in the boot of the car

    The original Z50R engine needed work so I threw together a spare Z50A engine and put the bike together as a bike for Nichole to ride, both of my sons learned to ride on this bike and the Z50A engine has never missed a beat but it was time to put the original engine back in place, originally it was going to be a stock rebuild, then I was going to use a 94R 12v crank, head and ignition system but in the end I decided to go with what I call a reverse 88cc engine with a 47mm bore and a 52mm stroker crank for 90.22cc.

    Sitting in the shed waiting for another ride:
    DSC02285.jpg


    Here is my eldest son Pirate Monkey learning to ride:
    DSC06096.jpg


    Currently fitted with a Z50A Engine running a stock exhaust and an XR/CRF70 carb and intake:
    DSC06207.jpg


    The original engine has been sitting in a box and on the bench for quite some time:
    DSC00048.jpg


    Finally on the starting grid ready to assemble:
    DSC02187.jpg


    Back in the day it was quite common to collect old engine oil and tip it into anything that you wanted to preserve or you
    could paint it on your pailing fence, this engine was full of a black oily sludge that left a tide mark stain that I could not
    remove even glass blasting could not get rid of the tide mark, every engine component was stained:
    DSC02193.jpg


    Rebuilt transmission was lightly glass blasted with new circlips, thrust and spline washers installed, inspect all transmission
    components carefully under an illuminated magnifying glass to check for wear or cracks, for a race or road bike I prefer to
    Flaw Check the parts - http://www.dymarkindustries.com/prod...ction#tab-id-1
    DSC02201.jpg


    I was originally going to use a 12v crank and ignition system from an old 94R that I had stashed away:
    DSC02210.jpg


    Here is the stained shift shaft from the original engine, hard to remove the stain from the plated parts:
    DSC02219.jpg


    After looking through the parts I had put away I decided to use a DRP 52mm "Pork Chop" stroker crank with a 47mm bore for
    a 90cc capacity, I have always wanted to compare this set-up with a 52mm bore x 41.4mm stroke 88cc engine combo:
    DSC02230.jpg


    Cases torqued up with new transmission bearings installed and the old case bolts were polished up on the buffing wheel:
    DSC02238.jpg


    Kickstart return spring, gearshift spindle, transmission shift star, oil filter screen and small primary gear installed:
    DSC02241.jpg
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    PERFORMANCE, REPRODUCTION AND OEM PARTS TO SUIT OLD AND NEW HONDA AND OTHER 4 STROKE MINIBIKES AND MOTORBIKES INCLUDING KAWASAKI, YAMAHA AND SUZUKI.

    Parts to Suit: Honda Z50A, Z50J1, Z50JZ, Z50R, Z50JDM, Z50M, QA50, QR50, MR50, XR50, CRF50, ATC70, CT70, CZ100, MSX125 (Grom), ST70, SL70, XL70, TRX70, XR75, XR80, TRX90, Kawasaki KLX110 and Z125 models to name a few.

  2. #2
    Forum Founder Classic Honda 50's's Avatar
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    A small Worcestershire Sauce bottle is perfect as an oil dispenser for engine assembly, squeeze for a drop of oil at a time:
    DSC02256.jpg


    Oiling up a TB Parts Heavy Duty clutch assembly ready to fit to the engine, disassembled ready to start:
    DSC02253.jpg


    Darker steel clutch plate goes first against the throw-out arms of the clutch:
    DSC02257.jpg


    Lubricate the clutch housing, clutch centre and first steel plate, assemble with the four small clutch springs:
    DSC02258.jpg


    Oil the first friction disc on both sides with the oil that you use in your engine:
    DSC02259.jpg


    Sit the clutch friction disc onto the splines of the clutch centre on the first steel clutch plate:
    DSC02260.jpg


    Oil the second steel clutch disc on both sides:
    DSC02261.jpg


    Install the second steel clutch disc on top of the first friction disc:
    DSC02262.jpg


    Oil the second friction disc on both sides and install it on top of the second steel clutch disc:
    DSC02265.jpg


    Oil the third steel clutch disc on both sides and install it on top of the second friction disc:
    DSC02267.jpg



    Oil the third friction disc on both sides and install it on top of the third steel clutch disc:
    DSC02269.jpg


    Oil the fourth steel clutch disc on both sides and install it on top of the third friction disc:
    DSC02270.jpg


    Install the clutch C clip to lock the clutch plates in place.
    Classic Honda 50's Australia - Visit our online store at -Hidden Content

    PERFORMANCE, REPRODUCTION AND OEM PARTS TO SUIT OLD AND NEW HONDA AND OTHER 4 STROKE MINIBIKES AND MOTORBIKES INCLUDING KAWASAKI, YAMAHA AND SUZUKI.

    Parts to Suit: Honda Z50A, Z50J1, Z50JZ, Z50R, Z50JDM, Z50M, QA50, QR50, MR50, XR50, CRF50, ATC70, CT70, CZ100, MSX125 (Grom), ST70, SL70, XL70, TRX70, XR75, XR80, TRX90, Kawasaki KLX110 and Z125 models to name a few.

  3. #3
    Forum Founder Classic Honda 50's's Avatar
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    TB Parts Hi Volume oil pump primed and installed with the hole in the engine case drilled with a 1.5mm drill:
    DSC02272.jpg


    Large primary gear installed with securing clip in place:
    DSC02273.jpg


    Clutch installed with locking nut torqued up to spec and locking washer tab folded down holding the nut in place:
    DSC02277.jpg


    Behind the stator plate, cam chain adjuster assembly in place, oil pump drive gear secured, engine oil seals ready to install:
    DSC02280.jpg


    TB version 1 race head, port work around bowl area, intake port matched to intake manifold, 3 angle valve job, polished
    combustion chamber, 47mm alloy cylinder:
    DSC02630.jpg


    Here is the 94R GK4 roller bearing cam head that I was going to use, the 19mm/16mm valve combination with small
    combustion chamber and ports can be a bit of a restriction compared to a 25mm/22mm valve combo race head:
    DSC02632.jpg


    TB Parts V1 race head:
    DSC02638.jpg


    I have had this stator plate put aside from another Z50R that I purchased a few decades ago, it is in as new condition,
    had intended to go 12 volt but wanted to compare this 47mm x 52mm 88cc with a 52mm x 41.4mm 88cc engine side
    by side on the dyno and see how the reverse 88 performs:
    DSC02635.jpg


    The flywheel looks like new just like the stator, ready for a top end build:
    DSC02637.jpg


    Head studs and dowels in place as well as the 47mm piston with rings installed to suit the 52mm stroker crank:
    DSC02655.jpg


    View of the motor from the clutch side prior to the cylinder installation:
    DSC02656.jpg


    View of the motor from the stator side prior to the cylinder installation:
    DSC02658.jpg
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    PERFORMANCE, REPRODUCTION AND OEM PARTS TO SUIT OLD AND NEW HONDA AND OTHER 4 STROKE MINIBIKES AND MOTORBIKES INCLUDING KAWASAKI, YAMAHA AND SUZUKI.

    Parts to Suit: Honda Z50A, Z50J1, Z50JZ, Z50R, Z50JDM, Z50M, QA50, QR50, MR50, XR50, CRF50, ATC70, CT70, CZ100, MSX125 (Grom), ST70, SL70, XL70, TRX70, XR75, XR80, TRX90, Kawasaki KLX110 and Z125 models to name a few.

  4. #4
    Moderator dex's Avatar
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    Tease ,,!!!
    its engine oil madge ,,,
    Your soaking in it ,,!!

  5. #5
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    �� nice. I have a real soft soft spot for R models.

  6. #6
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    Just added new pictures above.

    My goal was to collect one of every Z50R from 79 to 99 but I got side tracked with multiples of each model, then Nichole worked out what was happening

    The Red Z50R's from 79 to 89 are my favourites.

    These engine cases were media blasted with fine white sand then polished with lemon steel wool soap pads quite a few years ago and are still as good as the day I packed them away:

    DSC02665.jpg
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    PERFORMANCE, REPRODUCTION AND OEM PARTS TO SUIT OLD AND NEW HONDA AND OTHER 4 STROKE MINIBIKES AND MOTORBIKES INCLUDING KAWASAKI, YAMAHA AND SUZUKI.

    Parts to Suit: Honda Z50A, Z50J1, Z50JZ, Z50R, Z50JDM, Z50M, QA50, QR50, MR50, XR50, CRF50, ATC70, CT70, CZ100, MSX125 (Grom), ST70, SL70, XL70, TRX70, XR75, XR80, TRX90, Kawasaki KLX110 and Z125 models to name a few.

  7. #7
    Moderator Diggs's Avatar
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    Quote Originally Posted by Classic Honda 50's View Post
    My goal was to collect one of every Z50R from 79 to 99 but I got side tracked with multiples of each model, then Nichole worked out what was happening
    Hahahah! Busted Jaimie!!!!
    Rigby "No dude, you're doing it wrong! Righty-tidey, lefty-losey! Not lefty-tidey mess it up because you're a loser!"

    ZRX1200S, RGV250 VJ22, Skyteam T-Rex, Z50J1 '78, XV250 Virago

  8. #8
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    At one stage I think that I had seven 1983 Z50R's, still have three 83R's in the shed, it is hard to hide that many of the same model when your missus knows her stuff.

    Had to go back to the principle of "Happy Wife - Happy Life"
    Classic Honda 50's Australia - Visit our online store at -Hidden Content

    PERFORMANCE, REPRODUCTION AND OEM PARTS TO SUIT OLD AND NEW HONDA AND OTHER 4 STROKE MINIBIKES AND MOTORBIKES INCLUDING KAWASAKI, YAMAHA AND SUZUKI.

    Parts to Suit: Honda Z50A, Z50J1, Z50JZ, Z50R, Z50JDM, Z50M, QA50, QR50, MR50, XR50, CRF50, ATC70, CT70, CZ100, MSX125 (Grom), ST70, SL70, XL70, TRX70, XR75, XR80, TRX90, Kawasaki KLX110 and Z125 models to name a few.

  9. #9
    Moderator Diggs's Avatar
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    Quote Originally Posted by Classic Honda 50's View Post
    At one stage I think that I had seven 1983 Z50R's, still have three 83R's in the shed, it is hard to hide that many of the same model when your missus knows her stuff.

    Had to go back to the principle of "Happy Wife - Happy Life"
    Recently did the same mate - down from 11 bikes to 6. Car can go in the garage - so the wife is happy/er.....................
    Rigby "No dude, you're doing it wrong! Righty-tidey, lefty-losey! Not lefty-tidey mess it up because you're a loser!"

    ZRX1200S, RGV250 VJ22, Skyteam T-Rex, Z50J1 '78, XV250 Virago

  10. #10
    Forum Founder Classic Honda 50's's Avatar
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    I learnt to pull the bikes apart and put them in black plastic tubs out of sight out of mind
    Classic Honda 50's Australia - Visit our online store at -Hidden Content

    PERFORMANCE, REPRODUCTION AND OEM PARTS TO SUIT OLD AND NEW HONDA AND OTHER 4 STROKE MINIBIKES AND MOTORBIKES INCLUDING KAWASAKI, YAMAHA AND SUZUKI.

    Parts to Suit: Honda Z50A, Z50J1, Z50JZ, Z50R, Z50JDM, Z50M, QA50, QR50, MR50, XR50, CRF50, ATC70, CT70, CZ100, MSX125 (Grom), ST70, SL70, XL70, TRX70, XR75, XR80, TRX90, Kawasaki KLX110 and Z125 models to name a few.

  11. #11
    Moderator Diggs's Avatar
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    Quote Originally Posted by Classic Honda 50's View Post
    I learnt to pull the bikes apart and put them in black plastic tubs out of sight out of mind
    Haha, yeah that works well with Z's (I dont count stuff in tubs in the official "Bike Count"). Full sized bike fairing, frames, engines and tanks are harder to hide!
    Rigby "No dude, you're doing it wrong! Righty-tidey, lefty-losey! Not lefty-tidey mess it up because you're a loser!"

    ZRX1200S, RGV250 VJ22, Skyteam T-Rex, Z50J1 '78, XV250 Virago

  12. #12
    Forum Founder Classic Honda 50's's Avatar
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    Need bigger tubs and more of them
    Classic Honda 50's Australia - Visit our online store at -Hidden Content

    PERFORMANCE, REPRODUCTION AND OEM PARTS TO SUIT OLD AND NEW HONDA AND OTHER 4 STROKE MINIBIKES AND MOTORBIKES INCLUDING KAWASAKI, YAMAHA AND SUZUKI.

    Parts to Suit: Honda Z50A, Z50J1, Z50JZ, Z50R, Z50JDM, Z50M, QA50, QR50, MR50, XR50, CRF50, ATC70, CT70, CZ100, MSX125 (Grom), ST70, SL70, XL70, TRX70, XR75, XR80, TRX90, Kawasaki KLX110 and Z125 models to name a few.

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  14. #13
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    Hi Jaimie, hows this one going. Centrifugal clutch or manual into this one?

  15. #14
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    TB HD Auto Clutch.

    Have finally got back on my feet after months with my back playing up, lost close to 15kg on a coffee, stress and worry diet and my back pain is good enough to get going again, have also been waiting on the new TB head cover set to seal up the engine ready to go TF.

    DSC03253.jpg

    Cheers

    Jaimie
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    PERFORMANCE, REPRODUCTION AND OEM PARTS TO SUIT OLD AND NEW HONDA AND OTHER 4 STROKE MINIBIKES AND MOTORBIKES INCLUDING KAWASAKI, YAMAHA AND SUZUKI.

    Parts to Suit: Honda Z50A, Z50J1, Z50JZ, Z50R, Z50JDM, Z50M, QA50, QR50, MR50, XR50, CRF50, ATC70, CT70, CZ100, MSX125 (Grom), ST70, SL70, XL70, TRX70, XR75, XR80, TRX90, Kawasaki KLX110 and Z125 models to name a few.

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  17. #15
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    Wow sorry to hear about your back. I recently had 2 months off with a pinched nerve in the neck , so I know how you feel.
    That engine looks smick

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  19. #16
    Forum Founder Classic Honda 50's's Avatar
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    Hurt my back 24 years ago and now have my L5/S1 disc missing, but 24 years of back pain is the least of my worries at the moment as I have no feeling in my right eye thanks to two brain tumor ops and was rushed to the eye specialist today with two ulcers on my right eye that can cause blindness or a brain infection, doc said if I had any feeling in my eye I would be in hospital till next week and heavily sedated.

    Life goes on anyway, I had our last training session with my PCYC 17's A grade soccer team tonight, soccer training and a good dose of Z50's is all I need to make me feel better
    Classic Honda 50's Australia - Visit our online store at -Hidden Content

    PERFORMANCE, REPRODUCTION AND OEM PARTS TO SUIT OLD AND NEW HONDA AND OTHER 4 STROKE MINIBIKES AND MOTORBIKES INCLUDING KAWASAKI, YAMAHA AND SUZUKI.

    Parts to Suit: Honda Z50A, Z50J1, Z50JZ, Z50R, Z50JDM, Z50M, QA50, QR50, MR50, XR50, CRF50, ATC70, CT70, CZ100, MSX125 (Grom), ST70, SL70, XL70, TRX70, XR75, XR80, TRX90, Kawasaki KLX110 and Z125 models to name a few.

  20. #17
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    So, any chance the A motor that came out be for sale?

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