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Race Replica Nirvana: 1991 YZR500 Replica (RZ500)…..And It’s Legal!

Race Replica Nirvana: 1991 YZR500 Replica (RZ500)….And it’s Legal!

Update 11.11.2011: Back on eBay but with new pictures and a lower purchase price. eBay indicates the last auction went in the $27k range. Thanks to everyone who emailed that this one was back online. Links updated but new pictures can be found with the auction. -dc

Did you do a double take? Wayne Rainey might have to look closely to make sure something with two wheels isn’t missing from his house. We’ve had a couple of top shelf replica builds on RSBFS and each one seems to get better. This one should be hard to top.

The YZR500 replica bodywork really makes the bike. According to the seller they are an exact copy molded from a set off a YZR500. Nice! Bodywork can be a real pain in the behind when trying to make your project look like something that rolled out of a factories R&D department.

Yep, it has been rebuilt and breathed on.

Take a breath, here are the details

As a young impressionable man growing up, I have very fond memories of watching the Moto GP 500cc two stroke Grand Prix racing. The fastest riders in the world on the fastest machines. Kenny Roberts, Eddie Lawson, Wayne Rainey, Kevin Schwantz. It was a special time in racing. My fist bike, a 1984 Yamaha RZ350 was as close as I could get to those incredible machines. Yamaha, of course, never offered the YZR 500 to the public. It was the pinnacle of their race technology.

About 5 years ago I began the project of building a replica of the 1991 Yamaha YZR 500, as raced by the great Wayne Rainey. No expense was spared in this incredible build. What does it take, besides big $$$, to complete such a build.

First and foremost, I commissioned master bike builder and fabricator Wyn Belorusky for the build. Wyn can fabricate just about anything out of billet aluminum. In addition, he built for himself a YZR500 replica which has been featured in several magazines internationally.

The Build began:

Chassis:

Finding a titled frame was not easy, but patience pays off. A real Japanese RZV500 frame, which is the lighter aluminum version of the RZ500 steel frame offered elsewhere. 11 digit VIN, titled in Florida, in my name. The sub frame has been modified by Wyn. He installed custom billet Y supports, eliminating the stock sub frame bracing to clean up the rear of the bike for use with YZR bodywork. After all machine work was complete, the frame was freshly powder coated black.

Aprilla RS250 gull wing swingarm. This is an ideal choice, having the same length as the stock RZV swing arm, with the look of the YZR 500. Extensive modification was performed by Wyn to fit this swing arm to the RZV frame, shock linkage, and rear brake hanger. Once fabrication was completed, the swingarm was also freshly powder coated black.

Suspension:

Wilbers rear shock, with ride height adjust and remove reservoir.

Wyn also fabricated and installed a separate billet adjustable ride height linkage strut for additional adjustment. New Ohlins steering dampener, custom fabricated mount by Wyn.

2007 R6 forks, modified lower triple tree to accept a RZV500 steering stem for installation. 2007 R6 wheels front and rear.

I have a small fortune in the brake setup on this bike; Brand new billet Brembo front brake calipers, custom braided brake lines front and rear from Yoyodyne, New Brembo Radial front master cylinder, R6 rotors front and rear, R6 rear master cylinder and caliper.

Motor:

I started with a complete low kilometer stock RZV500 motor, bench stock from Mr. Belorusky, thank you very much. The motor was crated and shipped to Martin Marino of Madmann Engineering. Along with the motor I purchased and supplied a complete Brand New Yamaha OEM top end, Brand new Yamaha RZV500 cranks, new clutch, and new OEM Yamaha gaskets. Martin did a full high performance build with mostly brand new parts to work with. His porting, milling, and modification to the reed cages makes these motors come alive! Check out his link.

http://www.madmanengineering.com/rz500.htm

It’s set up for premix in its current state per Martin’s recommendation. I have an oil reservoir and set up to run the oil injection, which will be included in the auction, should the new owner wish to run the injector. It can run safely on 93 octane, but the motor does like the race gas. Additionally, brand new mikuni 28mm flat slides were purchased and installed, along with K&N individual filters, and new throttle cables. The motor makes great power, is jetted just a little rich to be on the same side (I’m at sea level in Florida) and runs cool. The stock RZ has a habit of the rear cylinders running hot. Rick Lance added an accessory radiator to allow additional cooling of the rear cylinders

Exhaust:

Jim Lomas stainless steel GP chambers, with carbon fiber canisters. Built to order in Czechoslovakia, the quality and workmanship is amazing. The sound, weight savings, and performance are equally impressive. Wyn did a beautiful job in modifying the exhaust hangers on the pipes to fit with the new swing arm, and the upper pipes were gently molded to slightly point inward to replicate the upper YZR pipes on Rainey’s bike

Bodywork:

Many years ago, Wyn was fortunate enough to borrow a set of REAL Yamaha YZR bodywork from a 1991 works bike, just long enough to make molds. Genius! From these very molds comes the bodywork on my bike. It’s the real deal. The custom brackets Wyn fabricated for mounting the bodywork is nothing short of artwork. Additionally, all quick release pins and real Dzus fasteners were used. Careful custom modifications were performed to allow installation of the functional headlight and tail light. A custom windscreen was fabricated as well, which fits perfectly.

I saw Rainey’s 1991 YZR500 in Laguna at the 2005 MotoGP, and took many pictures. This was an invaluable reference point for the build, particularly matching the color and logos. Paint by Paula in Titusville, Florida performed the paint work. She used a very rich pearl white, along with a day glow orange (from the house of color) to match Rainey’s bike. No decals were used; all work was done with paint. It does look sweet, and correct to Rainey’s 1991 YZR500.

Miscellaneous:

The rearsets are custom fabricated by Wyn Belorusky. Included are two separate sets of rearset brackets, one for the stock position as pictured, and a set for the full race position. I initially had the race ones made, but then subsequently had a stock set made as I have only ridden the bike on the street. Again, both sets are included. They are beautiful. Wyn even machined the right side foot peg to fold up, to allow for clearance of the kickstarter when starting (like the stock RZV right side foot peg does). It’s the details that I love!

The dash was a custom fabrication setup with the tachometer mounted, a Daytona digital Temp gauge, and a GPS which can be used as a speedometer.

The sprocket cover was modified, by shortening the rear portion and milling out the holes. It turned out sweet. The right side engine cover, water pump, and left side sprocket cover were also sand blasted to give the appropriate GP look.

Wyn took the wiring harness and stripped any unnecessary wires, then cleanly wrapped and reinstalled all wiring. It’s very neat.

New 520 chain/sprockets, custom billet swingarm spools.

.

I really can’t even come close to listing all the fine details that went into this incredible build. I have many many pictures documenting the entire build. The bike needs a home with someone who appreciates what went into this project to achieve this final result. It’s awesome..

Everyone who does a build should do it for themselves first and foremost. I say that because I will nit pick here. My nit picky point being, if you spent all the money to replicate a 1991 YZR500, shouldn’t the pipes look period? Mild steel (or titanium if $$$ is no question) for the pipes would do the trick. A totally personal choice, just wondering since so much detail went into the bike.

They don’t get built overnight. That’s a RZV frame not the more common RZ500 frame. I’ve always thought it would be cool to track down an old Harris or ROC YZR frame and use that for the base of a YZR replica. If you’d like to drool a little more, check these replicas out of Australia out. I think you can buy the frames seperatley if you are do it yourselfer.

Remember, it is road legal too. I hope all the bargain hunters stopped reading a long time ago. I would be surprised if the reserve on this bad boy isn’t in the mid twenties. On one hand I say it is completely worth it. It is an absolutely beautiful bike that a lot of care, time and money was invested into. On the other hand after you get past the good looks and expert craftmanship you still have a spindly mid 80’s frame hiding in there. When you get into high dollar builds there are options out there, like the Aussie built replicas. Don’t get me wrong, I love the bike, I’m just sayin…… To get in the mix on this beautiful bike, simply click here.

Ian

17 Comments

  • What Aussie built replicas???
    Can you list a website?

    Thank you
    Scott

  • Scott,
    Up in one of the paragraphs I have “check these replicas out of Australia out”, click on the orange letters and enjoy.

  • I know he has over $30k plus into it… probably just in parts. i bet the reserve is high 20’s. Will someone pay that? No… not on ebay. Someone will have to look at the bike in person real close for that cash. It is sweet!

  • bzzzzt. its already up to 25-large with +3.5days to go!

    if i had the spare krinkle and were a bit less pragmatic i’d snap this up, lickety-split!

    wallymann from motown

  • Looks like the reserve is gone as well so it will find a new home.

  • rzv wynn had his yellow and black rz up on ebay once with a reserve at 30k which didn’t sell the first time. he ended up selling it years later for high 20s, i think. i’ve seen pictures of this bike for years and if i had less sense i’d buy this for sure. i can’t say that i’m not tempted, but i can’t do it without a little sacrifice. i think that this bike is worth whatever it sells for. it’s one of a kind and absolutely beautiful. 100% amazing.

  • There is also a canadian company that builds YZR500 and RGV500 replicas called Adjustment Tech.

    http://www.adjustmenttech.net/rg500.htm

    http://www.adjustmenttech.net/yzr500.htm

  • Hmmm, another nice alternative. I would assume a little less expensive than the ground up Aussie models.

  • Dam, was hoping to scare some folks away so I could buy it my self 🙂 Well worth the cash. Now, folks know it will sell…Wonder if the impulse buy would kick in. Spending $30k for a custom bike not seen? Guess if you went to see it and it was podged together you could bail on the deal. Anyone scared yet? 🙂 Crap…didnt think so. The bike will be aswome in person as well….

  • […] this is not the killer Yamaha YZR 500 replica posted by Ian last week. But it is a oil-injected (no need to mix) six speed two stroke that the […]

  • As much as I love it, I have to agree with Ian’s comment about the “spindly mid-80’s frame hiding in there” would be a deal killer for me. The basic structure just isn’t up to the level of the rest of the bike, and when you want or build a YZR500 factory replica like this, it would just have to have a contemporary twin spar aluminum frame (Spondon, Harris, TZR conversion, RS Aprilia, etc.).

  • Now that I have my own RZ500 based YZR replica, I can understand the thought process behind retaining the stock RZV frame.

    It is not ‘spindly mid-80’s frame’ – it is actually a pretty stout well designed perimeter frame, and the weight savings of going to a beefy twin spar design are really the only real bonus. And it look slike a proper lat 80’s YZR – remember, the early 80’s YZR’s where perimeter framed GP bikes.

    Anyway, I still think the mid to high $20K range for these bikes is a sketcy area – the price really reflects the labour and sum of the parts, not the actual value of the machine.

    Once I am done with mine i will probably have about $25K in the bike as well, but honestly, I would not expect to sell it for that price – the price simply reflects the time and labour to source and fabricate all the bits.

    But in the end, all these YZR replicas are just GP-bike wannabe projects with great heavy iron sleeved RZ500 motors in their chests. I am interested to hear the weight of this bike – mine currently sits at 377lbs all gassed up ready to ride. For $27K I would expect, no demand, that this YZR replica tip the scales at no more than 320lbs soaking wet.

  • Sold – Buy it now at $24,900

  • So it did. Hope it stays with the new owner for a little longer this time.

  • Nice bike I had a 94 YZF750R that was a fun project
    someone painted all black with crude stenciling

    pic

    https://lh4.googleusercontent.com/-pjXLMfB0pMY/ToC97rcxNTI/AAAAAAAACuY/ieyuQ__fwCA/s640/IMG_2704.jpg

    I repainted with decals to look like this

    pic

    https://lh6.googleusercontent.com/-HZcM9VwFqRQ/TZ9OlfQpQeI/AAAAAAAACCU/G4-aUi8vYAU/s720/100_0932.JPG

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