RS500

[500RG]

I will need a two-stroke oil tank and am really struggling for space now, on many of these builds they are positioned under the seat hump. I was not really keen on that idea as it locates 2 or 3 litres of oil at quite a high position and also then you have to remove the seat unit to refill or cut the seat unit up to……. either give flap access to filler cap, or have the filler cap proud of the seat unit. I wanted to try and centralise the weight, there is a fair gap between the bottom of the fuel tank and the rear exhausts, and I thought about fabricating an oil tank to fill this void. I tried to work out exactly how much space/volume I had to play with I tried positioning a few small cardboard boxes/containers under the tank – as I am not obviously running an air box this seemed the logical position.
I had an original oil tank from a RG500 which I purchased purely in case I wanted to use the hose fittings and oil level sensor, I tried fitting this under the tank and it was fouling the tank before it fully seated, I tried turning the oil tank through 180 degrees as it is an unusual shape and hey presto it fitted perfectly. Unfortunately, the oil tank is 30 years of age and the plastic had become very discoloured, I cleaned it the best I could and applied heat matting to prevent any damage from the exhaust headers. This should not be an issue as the oil tank sits directly above the exhausts on the RG500 and I will wrap the rear exhaust headers with some heat lagging tape anyway.

The aluminium bracket I manufactured to feed the fuel lines through acted as a place to fix one end of the oil tank to, I made another stainless steel bracket that sits on the rear sub frame rails to fix the other end of the oil tank to.

[500RG]

I am converting from a cable to hydraulically operated clutch, the three-piece billet clutch cover has a standard mounting to suit a cable.





I had to make a new mounting bracket; I had a choice of clutch slave cylinders. The black one is a Magura and the silver one is an ebay purchase.

[500RG]

I will probably go with the Magura, as you can see there is just enough room to fit it in, so it doesn’t clash with the carburettor and its pipework. I will also clean the mounting bracket up and radius/chamfer.

[500RG]

I decided to try a bell-mouth feed into the carburettors to see if this improves anything. RG500 engines always tend to be a bit of a compromise when it comes to fueling and air-filters. I have tried the individual ITG filters on each carb, which worked well, especially on top end, however they are so bulky that they run very close to the inside of the fairing – which usually has to be widened to accommodate them. I will be using Tripod filters on this build, and these can be fitted with the rubber bell-mouths I am trying and still leave approx. 50mm of clearance to the inside of the fairing.

[stusco]

Apr 18, 2020 8:53:51 GMT 1 500RG said:

I will probably go with the Magura, as you can see there is just enough room to fit it in, so it doesn’t clash with the carburettor and its pipework. I will also clean the mounting bracket up and radius/chamfer.

I take it that the slave wont fit on the standard cable fitting

[500RG]

Apr 20, 2020 17:58:26 GMT 1 stusco said:

Apr 18, 2020 8:53:51 GMT 1 500RG said:

I will probably go with the Magura, as you can see there is just enough room to fit it in, so it doesn’t clash with the carburettor and its pipework. I will also clean the mounting bracket up and radius/chamfer.

I take it that the slave wont fit on the standard cable fitting

I could have bodged the original fitting to accept the eBay slave cylinder, but the Magura cyl would not of been able to be used in the original fitting - hence why I made the new fitting.

[500RG]

I have located the rear shock remote reservoir between the rear exhausts – under the seat, again there is that much going on in the engine department I would have struggled to position it anywhere else. I know it is not the ideal position due to heat from the exhausts – but the space is larger than it looks and it’s a fair way down the expansion chamber length, so it is nowhere near as hot as the temperature at the headers.

[500RG]

I tried the Tyga fairing for size, making sure I had clearance on the radiator, lower exhausts, air-filters, side stand etc.

[Eyrey1]

hi pal not chatted for a while now .
thats a really stunning build again ! lol
mine is finnished just needs a couple of things doing
pics dont do mine justice you have to see it to take in all the detail i bet yours is the same .
if you know anyone after something a bit different 2 stroke 500 i think i would sell mine ,i would be gutted but i cant see me riding it .
its a ready made hybrid that is as new , no one has ridden it ,not a mark or scratch any where everything is new.

[Tobyjugs]

This is a very nice project

[muttsnuts]

nice build, coming along lovely, reminds me doing my 421, I am on with another at the moment, but its a 500cc twin this time, running R6 suspension etc, will get round to posting some stuff up in due course.

For now a couple of pictures of my 421, I've never got round to deciding what to paint it, so for now its like "batmans bike" !






I suspect your's is going to be much better than my 421, you decided what paint scheme its having, that's what I am struggling with at the moment

[500RG]

Apr 21, 2020 20:41:55 GMT 1 Eyrey1 said:

hi pal not chatted for a while now .
thats a really stunning build again ! lol
mine is finnished just needs a couple of things doing
pics dont do mine justice you have to see it to take in all the detail i bet yours is the same .
if you know anyone after something a bit different 2 stroke 500 i think i would sell mine ,i would be gutted but i cant see me riding it .
its a ready made hybrid that is as new , no one has ridden it ,not a mark or scratch any where everything is new.

Hi mate - how you doing?

Do you have any pictures / video you can post, I would love to see it.

Try posting it on RGV500 & RG r 500 facebook, you may get some interest.

So what are you planning on building next - when you sell this beast !

[500RG]

Apr 21, 2020 21:59:24 GMT 1 muttsnuts said:

nice build, coming along lovely, reminds me doing my 421, I am on with another at the moment, but its a 500cc twin this time, running R6 suspension etc, will get round to posting some stuff up in due course.

For now a couple of pictures of my 421, I've never got round to deciding what to paint it, so for now its like "batmans bike" !






I suspect your's is going to be much better than my 421, you decided what paint scheme its having, that's what I am struggling with at the moment

That is a lovely looking bike, not sure mine is going to be better - just a different interpretation !

No i'm not sure on paint / finish, I certainly do not want to cover all the carbon fibre - whats the point of that! It will probably be some subtle bespoke graphics + lacquer. I always like the motogp pre season bikes that are mostly carbon fibre body work + graphics, so may go along those lines - not sure to be honest, although it is 90% complete now it will still have to be fully stripped down for frame painting etc, as I had to modify the frame there are now places without anodising so I need to do something with that.

Get a thread going on your new build - I would love to see it.

Cheers

[500RG]

[muttsnuts]

Apr 22, 2020 7:44:56 GMT 1 500RG said:

Apr 21, 2020 20:41:55 GMT 1 Eyrey1 said:

hi pal not chatted for a while now .
thats a really stunning build again ! lol
mine is finnished just needs a couple of things doing
pics dont do mine justice you have to see it to take in all the detail i bet yours is the same .
if you know anyone after something a bit different 2 stroke 500 i think i would sell mine ,i would be gutted but i cant see me riding it .
its a ready made hybrid that is as new , no one has ridden it ,not a mark or scratch any where everything is new.

Hi mate - how you doing?

Do you have any pictures / video you can post, I would love to see it.

Try posting it on RGV500 & RG r 500 facebook, you may get some interest.

So what are you planning on building next - when you sell this beast !

I have a couple of videos of it running, one at Donnington and one going down the road, not sure if I can post them on here but will try, if not,send me your email and I'll email them to you

[Tobyjugs]

I love your comfortable race seat Dave.

[500RG]

I was not too happy with the RS250 rear wheel/Tuono front wheel combo, so have opted for these beauties instead

[muttsnuts]

lovely wheels, I have the exact same for my new RS project as well, extremely light

[500RG]

[mellorp23]

Can't wait to see the video of it being ridden in anger

[500RG]

[Eyrey1]

Apr 22, 2020 7:44:56 GMT 1 500RG said:

Apr 21, 2020 20:41:55 GMT 1 Eyrey1 said:

hi pal not chatted for a while now .
thats a really stunning build again ! lol
mine is finnished just needs a couple of things doing
pics dont do mine justice you have to see it to take in all the detail i bet yours is the same .
if you know anyone after something a bit different 2 stroke 500 i think i would sell mine ,i would be gutted but i cant see me riding it .
its a ready made hybrid that is as new , no one has ridden it ,not a mark or scratch any where everything is new.

Hi mate - how you doing?

Do you have any pictures / video you can post, I would love to see it.

Try posting it on RGV500 & RG r 500 facebook, you may get some interest.

So what are you planning on building next - when you sell this beast !i will post some pics in next day or so !  i want some bst wheels now in carbon but all the 5 weeks of work getting the forged wheels to fit and its money i wont get bak now so i doesnt make sence but they are lush !

[500RG]

[500RG]

[500RG]

[tipfinchy]

love this top quality build , when do you hope to have it running
mart

[500RG]

May 2, 2020 17:41:44 GMT 1 tipfinchy said:

love this top quality build , when do you hope to have it running
mart

Hi mate,

This is a re-post, it has been running and MOT’ed. I will be stripping it down in the coming months to get the frame and other items painted.

[500RG]

[tacky1]

Just a beauty. Can’t wait to see it finished.

[500RG]

I wanted some decent LED carbon fibre (real) indicators, theses (fake) ones are what I had to settle for.





I was never really happy with them, so I bit the bullet and ordered these sequential indicators.