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Post by 500RG on Mar 25, 2020 11:48:31 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!
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RS500
Mar 25, 2020 12:14:33 GMT 1
Post by 500RG on Mar 25, 2020 12:14:33 GMT 1
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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RS500
Mar 25, 2020 13:43:17 GMT 1
500RG likes this
Post by 4l04ever on Mar 25, 2020 13:43:17 GMT 1
Hi Lee. Get the pics up! I will get my tissues ready...
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RS500
Mar 25, 2020 13:57:55 GMT 1
Post by 500RG on Mar 25, 2020 13:57:55 GMT 1
Hi Lee. Get the pics up! I will get my tissues ready... Will do Rob - have you fitted that bodywork yet?
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RS500
Mar 25, 2020 13:59:28 GMT 1
Post by 4l04ever on Mar 25, 2020 13:59:28 GMT 1
No, but I moved it around the loft last week :-)
Need to get front end for my project. Got back end sorted and most of engine bits.
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RS500
Mar 25, 2020 14:06:28 GMT 1
rd84 likes this
Post by 500RG on Mar 25, 2020 14:06:28 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. 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 specification. 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 and Performance Fabrication billet clutch cover
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richb
Thrash Merchant
Posts: 354
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RS500
Mar 25, 2020 14:10:20 GMT 1
Post by richb on Mar 25, 2020 14:10:20 GMT 1
That is a beautiful bike. Are you using that bike as a donor or is the RS framed a completely separate bike thus going to end up with 2 beauties Rich
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richb
Thrash Merchant
Posts: 354
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RS500
Mar 25, 2020 14:12:21 GMT 1
Post by richb on Mar 25, 2020 14:12:21 GMT 1
Posted just as the answer appeared doh
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RS500
Mar 25, 2020 14:20:29 GMT 1
Post by 500RG on Mar 25, 2020 14:20:29 GMT 1
Posted just as the answer appeared doh Hi Rich, The original Walter Wolf turned into the blue and white bike, the RS500 is another build, using a converted 400 engine
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Post by 500RG on Mar 25, 2020 16:58:34 GMT 1
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RS500
Mar 25, 2020 23:27:18 GMT 1
Post by donkeychomp on Mar 25, 2020 23:27:18 GMT 1
That blue and white RG is perfect. You must be a very happy camper!
Alex
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RS500
Mar 26, 2020 0:15:48 GMT 1
Post by JonW on Mar 26, 2020 0:15:48 GMT 1
Wow! lovely! Great project.
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Post by 500RG on Mar 26, 2020 12:21:00 GMT 1
The next area to look at is the inside of the frame in relation to the clutch cover, I purchased a 3-piece billet cover from Performance Fabrications which is narrower than the standard cover, and will allow clutch removal with the engine in situ. The inside of the RS frame can be marked in relation to the clutch cover, the engine removed and then the inside ‘skin’ of the frame cut away to give clearance and then the inside can be strengthened by an aluminium fabricated section being manufactured and welded in place. Also, a cast hole in either side of the RS frame was ‘filled’ with an aluminium plug welded into position and dressed back.
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RS500
Mar 26, 2020 12:26:52 GMT 1
Post by 500RG on Mar 26, 2020 12:26:52 GMT 1
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RS500
Mar 26, 2020 16:09:24 GMT 1
Post by 500RG on Mar 26, 2020 16:09:24 GMT 1
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Post by 500RG on Mar 26, 2020 16:15:36 GMT 1
If you look carefully at the bracket below the head-stock , the front hole mounts via a rubber vibration damper to one of the cylinder head bolts, on both sides of the engine to support the engine. I did not like the idea of this method, hence why I went for an engine cradle.
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RS500
Mar 28, 2020 14:38:32 GMT 1
Post by 500RG on Mar 28, 2020 14:38:32 GMT 1
Other modifications to the frame. Power Valve / battery mounting lugs Steering damper mounting lug Fairing mounting bracket plate Frame hole plugged and welded Radiator mounting bracket Engine mounting brackets, bolts and nuts Plus, a couple of items purchased from Performance Fabrications Stainless Steel expansion chambers and carbon end cans Pace core curved high capacity radiator (not this actual one)
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RS500
Mar 29, 2020 12:46:27 GMT 1
Post by 500RG on Mar 29, 2020 12:46:27 GMT 1
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RS500
Mar 29, 2020 12:52:47 GMT 1
Post by stusco on Mar 29, 2020 12:52:47 GMT 1
What’s the kickstart off?
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RS500
Mar 29, 2020 13:04:30 GMT 1
Post by 500RG on Mar 29, 2020 13:04:30 GMT 1
What’s the kickstart off? Suzuki RM250 - but it has to be a certain year as they changed them
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RS500
Mar 29, 2020 13:08:45 GMT 1
Post by stusco on Mar 29, 2020 13:08:45 GMT 1
Looks good is it any shorter?
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RS500
Mar 29, 2020 13:27:15 GMT 1
Post by 500RG on Mar 29, 2020 13:27:15 GMT 1
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RS500
Mar 29, 2020 13:29:39 GMT 1
Post by 500RG on Mar 29, 2020 13:29:39 GMT 1
Looks good is it any shorter? A smidgen - not much in it, you can see if you look at the photos of before and after.
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Post by 500RG on Mar 29, 2020 13:31:34 GMT 1
Looks good is it any shorter? Quite a bit lighter though and much better looking than the original kick start lever.
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Post by 500RG on Mar 29, 2020 16:14:19 GMT 1
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Post by 500RG on Mar 30, 2020 9:55:10 GMT 1
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Post by yamark on Mar 30, 2020 18:51:59 GMT 1
Just a superb build. Love the attention to detail. I had 2 RG500's back in the day, brilliant bikes.
Following with interest
Cheers, Mark
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Post by 500RG on Mar 31, 2020 9:28:13 GMT 1
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RS500
Apr 1, 2020 10:20:36 GMT 1
Post by 500RG on Apr 1, 2020 10:20:36 GMT 1
It is now time for some careful planning, most of the cables need to head over the top of the engine and either around or through the headstock. Other items that will have to be put in that location are. Battery, Power Valve Actuator, Coils, some pipe work for the radiator – which I would also like an electric fan, the two rear exiting expansion chambers, fuel lines, wiring loom (which I will be making from scratch), ideally the 2 stroke oil tank (this could possibly go under the rear seat unit). Also, the electrical ancillaries (CDI, Power Valve control unit, fan controller, regulator/rectifier).
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Post by 500RG on Apr 1, 2020 10:48:11 GMT 1
A Tyga rear sub-frame was fitted, the bottom support arms were removed as the under-seat exhausts would clash. Mark Dent manufactured a new aluminium support, which locates on a new square tube section welded into the sub-frame and mounts on the top shock mount, a lovely piece of kit. You can also see the Tyga rear sets which I decided to go with, at some point in the future I would like to convert to folding foot pegs if possible.
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