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Post by botty on Feb 8, 2014 0:10:42 GMT 1
I built this bike a few years ago. Not getting many miles on it due to a worn clutch basket bearing being shot, making changing gear and finding neutral difficult. It runs pretty well, but I'm going to rebuild the engine following a few engine modifications. This is my 400, with FZR 400 rear end with shock mounts added. RGV front end, rear sets and Allspeeds.Other than that it's pretty standard.THe pipes in the first picture didn't work very well so were changed.  Dave Reynolds fitted a Zeeltronic to my ACRD/YPVS project. Saw my 400 and suggested he could fit a programmable Zeeltronic to it, and gain a bit of power. He took the bike and had it dyno'd before any work took place to give a base power run to see what improvements are made. To my surprise and everyone else's at Projex it made 50bhp and 40 at 6k revs. I thought the txt was going to say it had blown up. Which I expected it to with the clutch knackered. Dave has made a base plate and fitted some pick ups from as he puts it "some 4 stroke" made a trigger out of an old points cam  I got some small can Gibsons off Ebay which need some work, but were not dented. Turns out 1 fits c/d the other fit e/f So moved the bracket to suit.And one header was shorter then the other, been cut down for some reason.     Just need refinishing now Muttsnuts kindly sold me some barrels which have just come back from Mick Abbey    With the modifications we are doing Mick has suggested (won't hold him to it)to expect 60+bhp and more if I change to Kenny pipes. Which when funds allow I'll get some. Will post up results along the way after each change. I don't expect the motor to hold on much longer. Anyone got a good crank??? |
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Post by 1966baz on Feb 8, 2014 19:59:46 GMT 1
Like it very much Botty, keep posting the progress. Sold all my RD400 stuff so can't help.
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Post by botty on Feb 9, 2014 9:41:57 GMT 1
Thanks Baz.
I'll keep it updated.
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Post by botty on Feb 17, 2014 0:22:58 GMT 1
I've been getting some txt's from Dave who's doing the ignition. He's got it running with the programmable ignition fitted that he has "pieced" together using various components. Including "Gary Jay" a CDI from an RGV 250. Which incidentally has gone pop,it was running 17volts and blew the dash bulbs too.Found to be a little nylon spacer on the brushes. He thought he had finished and was putting the tank on for a test ride. Anyway he's got hold of another CDI off ebay which will be here in the week. Possibly dyno it again next weekend. Dave is unsure what/if any gains will be made after it's first dyno run of 50bhp. He was not expecting that figure.He is sure some gains will be made. A few bhp throughout the rev range would be good. Then I've got Mick Abbey tuned barrels to go on.    The cover wouldn't fit so Dave made a adaptor ring.   |
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Post by dusty350 on Feb 17, 2014 8:51:14 GMT 1
Morning Botty, Some nice work there mate, and it's always nice to see a good 400 special. I remember you building this when I frequented the Aircooled forum. Still have a soft spot for aircooled 400's, sometimes regret selling my last 400e special, especially as you never see aircooled Rd's around now. Hope you get it running well for summer. Regards Dusty  |
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Post by rich on Feb 17, 2014 12:50:51 GMT 1
Good stuff, Dave looks like a talented guy!
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Post by botty on Feb 17, 2014 20:57:01 GMT 1
Morning Botty, Some nice work there mate, and it's always nice to see a good 400 special. I remember you building this when I frequented the Aircooled forum. Still have a soft spot for aircooled 400's, sometimes regret selling my last 400e special, especially as you never see aircooled Rd's around now. Hope you get it running well for summer. Regards Dusty Thanks Dusty. Things are moving in the right direction, after getting over a few teething problems. So to speak. You built some cracking AC's. we both read from the same hymn sheet. Now your doing the same quality work to water cooled |
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Post by botty on Feb 17, 2014 21:00:38 GMT 1
Good stuff, Dave looks like a talented guy! He is very clever. He certainly knows his stuff. He starts to explain things that go over my head. He has worked on a few bikes off this forum including setting up "the mangler" He sent this text. I just let him get on with it. I know he wants it the best it can be. Cdi number one spark only on one cylinder, checked everything out and cdi seems to be duff. Cdi number two spark on both sides but only wants to run properly with anomolous settings then when reved to 5,000rpm fuse blows and bike cuts out turns out cdi number two is frazzled creating short across capacitance (fuse blew due to cdi failure). I have had the suzuki cdi's fail in exact same way before when using on ns400 (may be a wireing issue or less likely something to do with extra load. Cdi numbe 3 (zeel one) running on two nicely with anomolous settings again (I need to invert the signal from the pick ups (had this same thing before due to polarity of pulse from coils making zeel fire off back of rotor blip rather than front ie the kawasaki pick ups I'm using wound in different direction to suzuki ones (but same as honda where I have seen this before), it's to do with the left hand/right hand rules when working out current directions in inductances, you may like me have memory of th is from O level physics. So tommorow I need fuses and maybe neutral and oil bulbs as seem to have lost these when fuse blew. Then re-wire pick ups to get decent static angle (signal off front of rotor blip should then run off normal settings) and wire in zeel cdi properly and tidy everything up and mount boxes on tray, check it's charging properly and strobe up the ignition with timing disc for calibration of static angle and signal delay compensation. That should be it as nothing I can think of should cause the cdi to fail on this set up. |
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Post by marddy on Feb 18, 2014 12:51:42 GMT 1
Your bike looks sexy...those assortment of parts has really combined well.
How is the ignition + the zeel? Any diff?
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peacey
Drag-strip hero
Posts: 271 
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Post by peacey on Feb 24, 2014 0:08:48 GMT 1
How does it go with the tune? does it handle well with the upgrades?
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Post by botty on Feb 24, 2014 2:36:04 GMT 1
Can't comment on any improvements yet chaps.
I haven't got the bike back from Dave. He's going to dyno it with the new ignition. It's unlikely we will improve much on 50 bhp as the points could have been working at the optimum for peak revs.if we get provement throughout the revs. We'll be happpy. Once the ignition is tested. I'll fit the Abbey tuned barrels and go to the dyno again.
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