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Post by 500RG on Oct 4, 2017 14:44:06 GMT 1
Hi Forum Members, I have decided to repost my RS500 build, as it was not finished and PhotoFu*kit decided to stop sharing photos on 3rd party sites and a build is pretty much useless without photos – so to recap This is the start of my new project an RS500 A couple of years ago I purchased a Suzuki RG500, a bike I have always wanted. The plan was to try and drag it into the 21st Century by updating and modernising where I could, this is the bike as I purchased it. A Japanese import RG500, totally standard apart from the seat hump and pushing out about 74bhp. The engine underwent a full engine rebuild, gas flowed and ported, tripod filters, bored 31.5mm diameter carbs, bespoke expansion chambers and Zeeltronic programmable ignition. Plus new body work, wheels, suspension, dash etc. This was the end result. I was pleased with the results, a modern looking bike that handles and now making 112.5bhp. One thing that always bugged me were the two rocket launchers (sorry expansion chambers) on display under the seat. As I wanted to keep the frame intact this was the only option I had, if I had cut the rear sub-frame and raised it several inches I could of hidden the under seat exhaust, err under the seat! So it was always on my mind, what could I have achieved if I did not have any restrictions or barriers, so the idea of the RS500 was born. An Aprilia RS 250 frame married with a RG500 engine, tuned and modern suspension, wheels etc. To be continued………………………
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Post by marsbar350 on Oct 4, 2017 23:27:23 GMT 1
the original incarnation looks great you must like making life difficult going again on it did the walter wolf fan club have anything to say about this
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Post by 500RG on Oct 5, 2017 10:44:03 GMT 1
Hi, No not had any comments from the WW Massive 😃
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Post by 4l04ever on Oct 5, 2017 12:42:09 GMT 1
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Post by 500RG on Oct 5, 2017 15:43:51 GMT 1
Hi, no I will not be using the Mark Dent fitting kit as I do not like the concept of the brackets bolting to the cylinder head bolts - even if fitted with rubber vibration fittings, I will make an engine cradle that picks up the original engine front mounts. I will be letting Mark Dent mod the rear sub-frame to suit the expansion chambers he's making me, he will also gas flow, tune and fully rebuild the engine - as he is a bit of a legend on these engines!
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Post by 500RG on Mar 20, 2018 16:49:08 GMT 1
The Engine as purchased is a RG400 that was imported from Japan by Suzuki Race based in Ashbourne. Alan goes out to Japan for 2 or 3 months a year and buys up bikes, engines and parts – fills a container then ships them back to the UK and sells them as complete bikes and engines, or strips them and sells parts. This particular engine was low mileage, approx. 7,500km (and when stripped the internal condition confirmed this). Luckily enough when I had finished the Walter Wolf modernisation, I managed to pick up a second hand set of RG500 barrels and cylinder heads – which were very low mileage and in very good condition, these are very difficult to find and very expensive! I actually purchased them from Darren Lane, who is an RG500 bike builder of some repute. Before anything could happen to the engine it was initially used to match up to the Aprilia RS 250, to allow the necessary modifications, new engine mounting brackets and bespoke engine cradle, plus frame spar clearance for carburettors, but this will be covered later.
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Post by donkeychomp on Mar 20, 2018 22:06:11 GMT 1
For feck's sake that isn't a bike...it's bike porn!
Alex
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Post by Denzil on Mar 21, 2018 8:38:32 GMT 1
I am loving the finished result, the blue bike. Now i like that a lot. Love the workmanship that has gone into it.
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Post by 500RG on Mar 21, 2018 14:32:52 GMT 1
The engine RG400 was stripped completely and all external parts and the RG500 barrels and cylinder heads were sent for vapour blasting at Projex Motorcycle Engineers. The rebuild and engine tuning was entrusted to Mark Dent of Performance Fabrications, who is the guru on these engines. The full engine spec is; All new bearings and seals, genuine Suzuki full gasket set, crank strip and rebuild, full engine tune, engine gas flow, crank web ignition pick up slot widened to allow greater static advance, modified carbon rotary valves, billet disc valve covers, complete Nova transmission and straight cut primary gears, TTW cougar red clutch, offset carburettor bore to 31.5mm and carb splitters plus a new generator
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Post by 500RG on Mar 21, 2018 14:45:01 GMT 1
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Post by yamark on Mar 21, 2018 20:01:43 GMT 1
Love these images, fabulous build. Following with great interest
Cheers, Mark
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Post by 500RG on Mar 28, 2018 10:29:45 GMT 1
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Post by yamark on Mar 28, 2018 17:26:41 GMT 1
Awesome, I really enjoy this sort of fabrication unfolding- great work
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Post by 500RG on Mar 29, 2018 15:21:44 GMT 1
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