RG - Extensive clean [Archive] - Page 2

Arronduke

13th January 2015, 22:08

Crikey... what fucking concern of hers is it how and when you spend money?

A man after my own words.... I could not have said it better....obviously not to the wife as that would mean sleeping with the dog and to be honest he stinks and his tongue is not something you want near your jewels... after all I'm not an Aussie.

BUT there is a time in your life when you just ignore all common sense and just do it....(Christmas is a great time as money is just spent - tyres are hidden in the festive spending period) RG got new tyres as did the GSXR11 which got a new rear. Yep three f#cken tyres in one go. That dam hurt.

It did not hurt as much as falling off on the kids track at the Honda camp in Jan and breaking 4 ribs. That dam hurt and still does. Home brew, tramadol and codeine is the only way to sleep and that is in a lazy boy chair, cant lay down in a bed and its been 10days.... cant cough, laugh, sneeze (worst) etc

But I have made progress and it was great... to have a rolling chassis.

http://i982.photobucket.com/albums/ae304/Dukeman2/20150107_182437_zpsa50d3363.jpg

All the bolts have been plated, bearings replaced. Everything new.

http://i982.photobucket.com/albums/ae304/Dukeman2/20150107_182446_zpsc258d57b.jpg

http://i982.photobucket.com/albums/ae304/Dukeman2/20150107_182454_zps7a18ca21.jpg
Yes that is red grease on the axel bolt. The sprocket bolts are M10 x 1.25 fine, fitted perfectly in to the crush drive. Just need to get some nice looking nuts. Wife has been saying that for some time but hey I need 5 and are on the look out.

http://i982.photobucket.com/albums/ae304/Dukeman2/20150107_182527_zps189a6651.jpg
Front is installed, again everything is new, forks are standard RG forks with Rick lance Emulator kit fitted.
Discs are RGV250 as are the caliper's still under revamp.

http://i982.photobucket.com/albums/ae304/Dukeman2/20150107_182535_zpsfd5a0a95.jpg
http://i982.photobucket.com/albums/ae304/Dukeman2/20150107_182611_zps45604197.jpg

The aim is to have an RG500 that looks standard but with a modern twist, tyres and brakes with suspension to match.

http://i982.photobucket.com/albums/ae304/Dukeman2/20150107_182621_zps3c6ae3c5.jpg
So far all good.

Arronduke

13th January 2015, 22:22

Looking good...Here is a picture of the new torque bar for the rear caliper mount, the old one went to the frame. No good for the GSX600F caliper.
Anyone got a GSX600F rear Disc?

http://i982.photobucket.com/albums/ae304/Dukeman2/20150107_182750_zps3935966f.jpg

Lets look closer.....

http://i982.photobucket.com/albums/ae304/Dukeman2/20150107_182808_zps2c0f9c07.jpg

My worst fear was confirmed.... no the wife has not found the tyre receipt. Worse.
Interference.

http://i982.photobucket.com/albums/ae304/Dukeman2/20150107_182826_zps31f88b77.jpg
What a f#cker... I guess a press will bend the torque bar a bit and no one will be wiser. Annoys me that 5mm has caused this issue.

Saying that when I did my Katana and fitted a 170 rear I had to bend that one too, but I expected to bend that one.

Reckless

13th January 2015, 22:50

Looking good...Here is a picture of the new torque bar for the rear caliper mount, the old one went to the frame. No good for the GSX600F caliper.
Anyone got a GSX600F rear Disc?

My worst fear was confirmed.... no the wife has not found the tyre receipt. Worse.
Interference.

What a f#cker... I guess a press will bend the torque bar a bit and no one will be wiser. Annoys me that 5mm has caused this issue.

Saying that when I did my Katana and fitted a 170 rear I had to bend that one too, but I expected to bend that one.

Would the torque bar with a bend tend to straighten under Braking load??
Could you put the Torque bar on the outside of the bracket on the swing arm and a machined spacer in the center of the bracket??
Wouldn't look quite as good but only an Idea??

SVboy

14th January 2015, 15:15

Is it wrong that I popped a semi after those latest pikkies? Shame about the torque bar.

Buddha#81

15th January 2015, 07:22

Is it wrong that I popped a semi after those latest pikkies? Shame about the torque bar.

Only a semi? I blow my load every time I visit this thread!:eek:

HondaLad

15th January 2015, 10:19

I'm saving my pennies in hope that it turns into a "finally finished it, unfortunately circumstances and other builds on the go dictate it must be sold..." type thread

imdying

27th January 2015, 14:21

I could not have said it better....obviously not to the wifeNaturally... one has to check over ones shoulder when even typing it :laugh:

It's all so clean, gonna be a shame to ride it!

Arronduke

14th February 2015, 23:12

Not sure why the big break since my last up date. Christmas / New Year, beer.
Sums it up!

Oh and the wife, so much more expensive when the they are on holiday.
A good woman should earn when they are mopping the floor. Ask yours, I'm sure see will agree.

FA has been done, spent the kids Christam money.
http://i982.photobucket.com/albums/ae304/Dukeman2/DSC00021_zps4b893278.jpg (http://s982.photobucket.com/user/Dukeman2/media/DSC00021_zps4b893278.jpg.html)

But wait, keep that zip up...Buddha.

Also in the mail were the rest of the bearings.
What surprised me was how tight everything was, freezer and heat gun made assembly no issue.

http://i982.photobucket.com/albums/ae304/Dukeman2/DSC00027_zps7855bc94.jpg (http://s982.photobucket.com/user/Dukeman2/media/DSC00027_zps7855bc94.jpg.html)[/IMG

[IMG]http://i982.photobucket.com/albums/ae304/Dukeman2/DSC00024_zpsb07992b9.jpg (http://s982.photobucket.com/user/Dukeman2/media/DSC00024_zpsb07992b9.jpg.html)

http://i982.photobucket.com/albums/ae304/Dukeman2/DSC00029_zps199a58aa.jpg (http://s982.photobucket.com/user/Dukeman2/media/DSC00029_zps199a58aa.jpg.html)
The rest of the shock bits, cleaned, plates, like new. I'm enjoying this rebuild. How much to do this to the wife? Hell just a new pneumatic cylinder neck seal replacement...

Now this is a great picture, these are just the part to get the guardy bit back on, all engine bolts etc are separated. This is just a rolling chassis.

http://i982.photobucket.com/albums/ae304/Dukeman2/DSC00028_zps943a042e.jpg (http://s982.photobucket.com/user/Dukeman2/media/DSC00028_zps943a042e.jpg.html)

.

yod

24th February 2015, 20:49

moar poasts!

Arronduke

18th March 2015, 20:53

The heart of the whole thing.....

http://i982.photobucket.com/albums/ae304/Dukeman2/DSC00373%20Large_zpslzuifpca.jpg

Yep them things are cranks and this dam thing has two, that means twice the cost for everything.
Cranks ready to go for rebuild with new bearings.

http://i982.photobucket.com/albums/ae304/Dukeman2/DSC00372%20Large_zps7itikb24.jpg
OEM crank seals, you could buy a wife for the cost of these things.

And the final result... ah just beautiful.

http://i982.photobucket.com/albums/ae304/Dukeman2/DSC00405%20Large_zpswjbf4g5a.jpg

http://i982.photobucket.com/albums/ae304/Dukeman2/DSC00407%20Large_zpsocwdxguc.jpg
http://i982.photobucket.com/albums/ae304/Dukeman2/DSC00406%20Large_zpsmeqcw7gd.jpg

All oiled up and in zip lock bags ready to go..

http://i982.photobucket.com/albums/ae304/Dukeman2/DSC00408%20Large_zpscjzunmig.jpg

and yes there has been a little progress, FA but powder coating done, calipers soon off for blasting.

http://i982.photobucket.com/albums/ae304/Dukeman2/DSC00409%20Large_zpsa6gwjqfc.jpg
http://i982.photobucket.com/albums/ae304/Dukeman2/DSC00410%20Large_zpsughduakr.jpg

http://i982.photobucket.com/albums/ae304/Dukeman2/DSC00368%20Large_zpsxgginzio.jpg

On order are many of the grommets needed, seems to be heaps at the pub but none suitable for the purpose I need them for.
Not putting shiity old ones back in, if your going to use a grommet it has to be at least in good nick, no f#cken reamed out lose 30+ year old grommet. Not me, I prefer my grommets young and supple.

mossy1200

18th March 2015, 21:03

All oiled up and ready to go..

grommets needed, seems to be heaps at the pub, if your going to use a grommet it has to be young and supple.

Project extension request granted.

ktm84mxc

19th March 2015, 07:36

Aren't Grommets like Nipples so the firmer the better , don't want them all cracked and weather beaten or pulled on .

Arronduke

27th March 2015, 21:29

Weekly report...FA done like usual. But I did find that the rear number plate cover did not have the right screws.. they are on order.
I'm starting to get anal.! (no being or taking anal)

But when an indicator has a rusty screw, plate it or replace it.

http://i982.photobucket.com/albums/ae304/Dukeman2/DSC00419_zpskvqlytmb.jpg

Exhaust control unit fitted and the CDI, old looking thing is the exhaust control module (really how many times do you have to say that) , cant plate that.

My wife wishes I had an exhaust control valve at night, she would turn it off. I've decided to stop the fart in bed and shove her head under the blankets trick. A normal married man thing to do when sex is not on the menu BUT ... don't do this when the bitch says NO!.......!

http://www.ronsonwriter.com/content/view/69/9/

Poor bastard, might not have happened if she could cook eggs.

Arronduke

20th May 2015, 21:47

Finally I have my black zinc plating back, only took two goes and 3 months. Anyway I'm pleased with what turned up second time. There are not to many places that do black zinc plating I have found... for car and bike parts I might add.

The foot pegs and mounts have been sitting looking at me for weeks. I wanted to get them polished but could not decide weather to pay or do it myself.
End result.. was I did myself. Then clear coat or clear powder coat? Then I stumbled across a product form the good old USA .. this stuff seal polished metal for months on end, when it does start to fade a quick polish is all that is needed and apply more sealant. So I got some and wow this is the shit. Time will tell how long it lasts but the reviews are good and I have lots of polish shit that needs looking after like my wire rims on my Kat.

http://i982.photobucket.com/albums/ae304/Dukeman2/IMG_2937_zps4tg7o9vs.jpg

I just happen to have a sand blaster in the shed, great tool. Before and after! Not looking for the major bling affect but nice and clean with some shine that lasts.
http://i982.photobucket.com/albums/ae304/Dukeman2/DSC00481_zps2h9ogedx.jpg

http://i982.photobucket.com/albums/ae304/Dukeman2/DSC00496_zpsxs855rn7.jpg

Head light, dash etc all installed with all new rubbers... obviously.
http://i982.photobucket.com/albums/ae304/Dukeman2/DSC00492_zpsegb195nz.jpg
http://i982.photobucket.com/albums/ae304/Dukeman2/DSC00500_zps1v7gzaj0.jpg

Back end looking good. I could cut the rear guard and open it up to show it off better but I will leave that to the wife's surgeon, and dam while he there he can beef up the front end! Those small head lights cant see shit. Aim is original look with some nice modern touches. After all we all know what happens to an old bags that spends to much $$$ trying to look young. End affect is well about 99 beers to look good to any normal male.

http://i982.photobucket.com/albums/ae304/Dukeman2/untitled_zpspj47yo5d.png

http://i982.photobucket.com/albums/ae304/Dukeman2/DSC00497_zpsw4w2ogv4.jpg

The brake caliper's seem to be taking a long time, I am getting closer. A little more sand blasting, painting and re kitting and good to go. My guess is we will be talking about this unfinished job again soon.

Still got lots of small shit to add but I'm starting to think time to start look at the motor. But I have to say I'm enjoying the build. Next up is assemble the engine empty and have it soda blasted. Then paint and assemble.

Final shot.
http://i982.photobucket.com/albums/ae304/Dukeman2/DSC00490_zpsinxxjbpw.jpg

SVboy

28th May 2015, 08:13

Thats a fabulous bike lift you have there. What are the details? Available in NZ?

Arronduke

28th May 2015, 20:31

SV I made the bike lift from plans off the internet.
I still have the plans somewhere if you want them.

husaberg

28th May 2015, 21:21

SV I made the bike lift from plans off the internet.
I still have the plans somewhere if you want them.

I hacked Arrons Computer this afternoon and amongst the midget porn was this.

http://www.advrider.com/forums/showthread.php?t=312843&page=

Reckless

28th May 2015, 21:58

SV I made the bike lift from plans off the internet.
I still have the plans somewhere if you want them.

I had a post typed out to say as much then didn't post it?
Was keen on seeing how you got the jack under without making the table to high to get the bike on?
Plans for me to if you can find them please :)

I hacked Arrons Computer this afternoon and amongst the midget porn was this.

http://www.advrider.com/forums/showthread.php?t=312843&page=

Thanks husa but the bloody hospital beds are $5-800 each 2nd hand on T/me.
A dedicated bike lift off Trade me is better at $495 and no alterations to do?
Keen on Aaron to find those plans if he'd be so kind :)

I've got this far but would like a real one
312387

husaberg

28th May 2015, 22:07

I had a post typed out to say as much then didn't post it?
Was keen on seeing how you got the jack under without making the table to high to get the bike on?
Plans for me to if you can find them please :)

Thanks husa but the bloody hospital beds are $5-800 each 2nd hand on T/me.
A dedicated bike lift off Trade me is better at $495 and no alterations to do?
Keen on Aaron to find those plans if he'd be so kind :)

I've got this far but would like a real one

Pg two ya silly Rabbit..........
http://www.advrider.com/forums/showthread.php?t=312843&page=2

Ok, sorry took my time, but have not been here.

Start, the base, is 2, 2200 x 40 x 40 x 6mm angle, back to back. Is a bit light, if doing it again, would use 25 x 50 x 4mm RHS (part of the superstructure at the front over the jack, is to prevent the base from bowing up, with weight on the table.

Legs are 25 x 50 x 2mm RHS, again a bit light, should use 4mm (hence reinforcing on front legs)

Table is 1800 x 880 made from 50 x 25 mm x 3mm RHS, with 20 mm particle board, and covered with 1.6mm sheet (that was from something else, and was what I based the lifts dimensions on).

The jacking pivot point, is 250mm up the front leg.

Some photos (it is still undergoing mods,)0
blah blah

Reckless

28th May 2015, 22:13

Pg two ya silly Rabbit..........
http://www.advrider.com/forums/showthread.php?t=312843&page=2

Fuck you expect me too get to page 2 after 10pm and a bourbon ?? Edit: are my to, too ,tooo's right way round? damn bourbon :P

Mmmm I see GTinAus has quite a detailed post on Page2 but no pics as I'm not a member I'm guessing :(

Cheers Husa :)

husaberg

28th May 2015, 22:17

Fuck you expect me too get to page 2 after 10pm and a bourbon ?? Edit: are my to, too ,tooo's right way round? damn bourbon :P

Mmmm I see GTinAus has quite a detailed post on Page2 but no pics as I'm not a member I'm guessing :(

Cheers Husa :)

I do now have some midget porn as well...........<_<
http://www.kiwibiker.co.nz/forums/showthread.php/174831-Bike-work-bench-and-ramp-for-sale

Reckless

28th May 2015, 22:19

I do now have some midget porn as well...........<_<

NA thanks mate full size and female for me :) :2thumbsup

SVboy

29th May 2015, 19:42

Cheers AD. I will remember that.....not that I have the talent to make one mind you!

Arronduke

6th June 2015, 20:15

Right I had to dig deep but I have found the plans for the bike lift.

When it is its lowest state its about 130mm off the ground, if I had purchased a low profile jack I could have made it a lot less.
Only a couple of things I would change....

If you are interested send me a PM with your email address and I will send you a copy.
I also searched pictures of completed stands which helped heaps.

http://i982.photobucket.com/albums/ae304/Dukeman2/IMG_3003_zpsino3swgo.jpg

Reckless

7th June 2015, 18:32

Right I had to dig deep but I have found the plans for the bike lift.

When it is its lowest state its about 130mm off the ground, if I had purchased a low profile jack I could have made it a lot less.
Only a couple of things I would change....

If you are interested send me a PM with your email address and I will send you a copy.
I also searched pictures of completed stands which helped heaps.]

PM sent :) you sir are a scholar and a gentleman , Thanks :)

Arronduke

11th June 2015, 20:56

Rick info sent.
cheers
A

Reckless

11th June 2015, 22:24

Got it :woohoo: you really are a scholar and a gentleman, my summer project :)

malcy25

22nd September 2015, 18:09

I spy the RG in the background!

http://trademe.tmcdn.co.nz/photoserver/full/413968492.jpg

Arronduke

23rd September 2015, 19:29

What can I say.. sure looks like my shed.... But I'm sure its not. Next beer stop I will have a look to see, maybe I'm missing something.
"smart ass".... I sure laughed with the comparison, how did Malcy stage this?

Does not look like much has been happening to that RG. Correct and wrong.
Wife has brought a horse. End of statement. My life is close to ending.... a horse is like a second wife that does not put out, demands everything and needs more attention than a 40+yr knob.:no:
So basically I'm fucked.

After trial and error old tyres can be glued on to kids shoes and they wear them, tried the wife's boots but the chunky tread was to obvious and she threw them back in my shed.
But thanks to water, corn beef and pumpkin as a stable diet there was enough cash to purchase some new parts... finally. Oh and mental note always send bits to your work and get yourself a credit card that NO one knows about.. When paying the credit card call it car service, school fees and fines. But to be honest council rates is the best after all we know what Len Dickhead Brown has done to those.

I have spent some cash and this was not a small sum. NZ customs made me to apply for an importers number, any purchase over $1000 needs an importer licence. This took ages, but arrive the parts did. So add the clearance fee, GST and handling fee they sure know how to rip you off.

Note from RG web site...anything from Maranello Engineering is going to be better than anything from Suzuki. Factories build to a price. Maranello builds to the state of the art, then puts a price on it. Have to agree this kit was not cheap, hence no progress for some time while I stole cash from all directions. Yep...I had to drip feed the dude...

This is a full rotary disc set from Italy, Maranello engineering. The work man ship is outstanding this company make a lot of RG500 parts. I used to re-line the discs for people but I decided I did not want to worry about disc liners and went for a total rebuild. The discs are aluminium hard anodised so no wear. All I have to do is get the clearances right and the kit comes with multiple thickness gaskets for the job.

http://i982.photobucket.com/albums/ae304/Dukeman2/DSC01964_zpstcdxffnn.jpg (http://s982.photobucket.com/user/Dukeman2/media/DSC01964_zpstcdxffnn.jpg.html)

Arronduke

23rd September 2015, 19:35

And to add on closer inspection, I saw a Lion Red can cooler.... :msn-wink: That cant be mine.
You would never see me with a Lion red.

See I foiled the plan... Malcy!

SVboy

24th September 2015, 12:50

Mmmmm Bike porn! Mmmmmmm.

Arronduke

7th October 2015, 06:55

Time to get some paint removed.

http://i982.photobucket.com/albums/ae304/Dukeman2/DSC01987%20Large_zpshyfjvk60.jpg

Vapour Blasting Services in Franklin did an outstanding job, highly recommended.
They advertise in the services section on trade me.

http://i982.photobucket.com/albums/ae304/Dukeman2/DSC01997%20Large_zpstlcnu5d8.jpg

http://i982.photobucket.com/albums/ae304/Dukeman2/DSC01998%20Large_zps6n9stmlz.jpg

http://i982.photobucket.com/albums/ae304/Dukeman2/DSC01999%20Large_zpsgyahqvky.jpg

http://i982.photobucket.com/albums/ae304/Dukeman2/DSC02001%20Large_zpsv8wkrwye.jpg

Remember these bloody things.......! I gave up and sent them along, they are now ready for painting.

http://i982.photobucket.com/albums/ae304/Dukeman2/DSC02000%20Large_zpsa7zxgnme.jpg

Right time to get me A in to G and get some paint, now the weather is warming up so paint will dry.

Arronduke

10th November 2015, 19:51

The painting has started, the motor parts have been washed and cleaned with prepsol to remove all traces of oils and grease.
I like to warm the paint can and the thing to be painted.

http://i982.photobucket.com/albums/ae304/Dukeman2/DSC02057_zpsarx0u7cr.jpg

And the paint for the crank cases, very very close to factory, I tried a test piece and was happy with the result. The covers use a higher gloss paint.
To add the reputation of Dupi.cololr and I was happy to use it. Low Gloss DE1634

Good quality masking tape and a scalpel is useful, cant imagine doing it another way.

http://i982.photobucket.com/albums/ae304/Dukeman2/DSC02054_zpsxgct3jgq.jpg

http://i982.photobucket.com/albums/ae304/Dukeman2/DSC02052_zpsfxrmmlub.jpg
ready to paint.
http://i982.photobucket.com/albums/ae304/Dukeman2/DSC02052_zpsfxrmmlub.jpg

The moment... need to be relaxed... 3 coats, 2 light 10min apart and one heavy coat to finish. Spray can has been warmed, thing to be painted warmed, wives car close, don't care ready to go.

http://i982.photobucket.com/albums/ae304/Dukeman2/DSC02055_zpsmfvtyjx9.jpg

looking good, I love that there is a 10min wait between coats.. ample time to relax and have a beer.

Arronduke

11th November 2015, 13:17

Righty Ho some more painting.

http://i982.photobucket.com/albums/ae304/Dukeman2/DSC02165_zpsapozabkq.jpg

Pumba

11th November 2015, 19:21

Righty Ho some more painting.

Fuck bro. How many USB cables do you own?

Arronduke

11th November 2015, 19:46

The painting goes on... all the engine casing parts but not the outer covers, they are a higher gloss paint.

Its going to take some masking for the upper engine block, it been cleaned twice with a hose, every hole blown out with compressed air. Yep its clean.
Mean while the heads are done, everyone like a good head job and I was not disappointed, it felt good. Nothing like a good head job to get the blood flowing.

http://i982.photobucket.com/albums/ae304/Dukeman2/DSC02183_zpsodopxzes.jpg

sugilite

12th November 2015, 19:23

Looking good! Great work! :drool:

Cheesy

12th November 2015, 19:28

Is that paint ok to use on bare aluminium without the primer?

Arronduke

12th November 2015, 21:07

Is that paint ok to use on bare aluminium without the primer?

According to the instructions yes.

Quoted by RG owner from the UK website, whom I have found out know more than I do... yes hard to believe, wife did not think it was possible but this lot know their shit.

yamagamma, on 31 Jul 2015 - 09:13 AM, said:
Dupli Color Engine Enamel Low Gloss Black DE 1634 is a very close match to the factory crankcase paint. The covers are slightly glossier. I did the stator cover, Cluch cover and the chain cover in Dupli Color regular Gloss black engine enamel and it looks very factory. No primer neccessary, just beadblast, wash thoroughly, and paint. I've used this stuff on of my race bikes and it holds up really well.

Arronduke

12th November 2015, 21:23

You have to love masking tape.. and I do. It has so many uses. While its not as good as duct tape which we all have to agree is the second best invention next to cable ties. The good old masking tape can still render someone immobile....

You have to have a love with masking tape.... what an effort. Shit it was hard to work out what was more expensive.... the beer or masking tape cause this took f#cken ages..

http://i982.photobucket.com/albums/ae304/Dukeman2/DSC02188_zpsdn2bvaih.jpg

http://i982.photobucket.com/albums/ae304/Dukeman2/DSC02189_zpswsfsoobo.jpg

http://i982.photobucket.com/albums/ae304/Dukeman2/DSC02190_zpsbav9xpis.jpg

http://i982.photobucket.com/albums/ae304/Dukeman2/DSC02191_zpsw23bi8e2.jpg

http://i982.photobucket.com/albums/ae304/Dukeman2/DSC02193_zps2i1o74uu.jpg

Ready to paint.... and I have an oven all set up to cure everything.! Been then there and done that..... use the oven inside, about 4pm on a Sunday... fatal mistake. House stuck for hours and wifey was not happy when it can to cook dinner an hour later... the whole house stunk..!

ruaphu

17th November 2015, 19:01

Yeah awesome job on the prep work, looks sweet once all done.

Re the oven, yeah i done the very same thing a few years back too when rebuilding the CBR. I was about as popular as blood puddin at vegan convention for a few days :)

Great thread man, been a good read thus far, keep the installments comin.

Cheers Ando

Sent from my iPhone using Tapatalk

Arronduke

18th November 2015, 19:43

Ruaphu, thanks for the great reply.

The build is coming along very slowly, as money can be found.

Painted, dam thing nearly fell over. That would have ripped my undies but true black cap style I caught it just in time.
Reason.... swinging it off different wires to paint underneath etc, once I worked that out it was good to go.

http://i982.photobucket.com/albums/ae304/Dukeman2/DSC02199_zpsgli1h9bt.jpg

http://i982.photobucket.com/albums/ae304/Dukeman2/DSC02196_zpscugkquwo.jpg
F#ck me not a beer in sight.... must be a Monday.

The finished piece, just needs to sit for a week and off to the bake oven.
http://i982.photobucket.com/albums/ae304/Dukeman2/DSC02208_zpsitmky1ce.jpg
http://i982.photobucket.com/albums/ae304/Dukeman2/DSC02209_zpsoobszhpi.jpg
Holly shit... I just realised that's fruit in my picture, what is this doing to my image? Wife is thinking after seeing an RG for 20K on trade me she wants to keep me alive long enough to finish the bloody thing. Bitch actually asked me if I could remember how to put it back together! "As long as my ass points to the ground and my knob can point to the sky I thing I can pull it off". "So yes!"

Mike.Gayner

18th November 2015, 19:54

Loving this thread. Keep it coming.

Arronduke

18th November 2015, 20:09

http://i982.photobucket.com/albums/ae304/Dukeman2/DSC02201_zpsmogcbzik.jpg
Right I have to deal with the heads and the studs....something I though I had better ask the wife about as she being dealing with this problem for 15 years...:laugh:
Her advise was to add some heat, tighten the nuts and screw it.... out.

Not going to argue here...

Nuts are in place and tightened... now just need some of the wife's leverage and pulling on the lower nut...:sick: and that stud is deflated and in to a snap lock bag.... a heat gun is great here and in the end I did not even use that. All studs where removed with little effort. No special tool was needed here. My plan old nuts did the job.

http://i982.photobucket.com/albums/ae304/Dukeman2/DSC02202_zpsahrsqh8a.jpg

Getting ready to send the cylinders of to be bored +.5mm with original Suzuki pistons.

And for the people thinking what the hell, the man is losing it... not a beer to be seen. Well you are correct, I got sick of cleaning bottles and tiding up in my shed. Some thing had to give so I found a high power. Yep anyone else that would like to improve themselves and forget about the bottle I can help. Its a journey well worth taking...

Its called KEGS... homebrew on tape. :eek:

http://i982.photobucket.com/albums/ae304/Dukeman2/DSC02217_zpspoq0ejxq.jpg

Arronduke

18th November 2015, 21:05

Here is an interesting question.... we all want to build our engines cheap, why spend a cent more than we have to spend, especially after I have worked out that 9/10 times you will never get your money back. Look up KX250 build to see what I mean. Its about the enjoyment of solving a mystery, a jigsaw puzzle, fighting your demons and proving every other fuKker wrong. Like cooking and yes I am a good cook, its as simple as reading a book. But yes I have made heaps of mistakes, I used to rebuild a FULLY worked RZ350 motor for a RD350LC frame in my twenties, I even brought a JMC swingarm and a Nos kit for it!. And that was some time ago. Walk to the shed in the back of the section, beer'S in hand, small garden shed nothing flash. Big enough to hold a work bench, a stereo and my chair. Rest of the bike was in the car port. A bigger shed was on order... like a larger garden shed, a garage was only a dream. Long story short first 30mins was spent fixing yesterdays work after being to pissed to do it properly and the second 30min was spent attaching bits in the wrong place, all before heading to the pub. But I tell you what that engine ran real good when it was finished. I have a picture somewhere but talk about shame on the paint job.

If short of time skip to here... after market gasket set sourced. After spending some serious and we are talking serious amount of cash rebuilding this thing why would you not buy everything original? One badly sourced part could destroy this engine. I don't want to even ask what it cost to rebuild an RG5 engine, casue I'm not counting. All I know is that the wife's keeps asking why we don't have any savings. All I can say is Fukc me but I have no idea, did you buy your lunch today? well its about leakage and the coffee here, bit of Mac D there and were broke.

Really bored.... start here!!!After market gasket and o-ring kit, from Italy like many of the other parts I have used. They ONLY specialise in RG500. Their parts work....I hope.

http://i982.photobucket.com/albums/ae304/Dukeman2/DSC02210_zpsjefyjann.jpg
http://i982.photobucket.com/albums/ae304/Dukeman2/DSC02211_zpsdm964shf.jpg
http://i982.photobucket.com/albums/ae304/Dukeman2/DSC02213_zpscvcywlvu.jpg
http://i982.photobucket.com/albums/ae304/Dukeman2/DSC02214_zps6he8qcep.jpg
http://i982.photobucket.com/albums/ae304/Dukeman2/DSC02215_zpsxuzeaumh.jpg

Discussion on after market parts... basically only use OEM unless the after market parts are 100% proven. I have the piece of mind of such. Any after market part has to be proven and identical replacement another one I often use is seal from seal house, but not this time. Bearings yes, but plan ones only, O-rings (in kit above) yes but not gaskets and seals. ALL OEM

sugilite

19th November 2015, 09:51

I reckon your taking the right approach with OEM vs Aftermarket. You can only do what you can do at the end of the day. The quality of those gaskets and seals look right up to the job to me. Good luck with it all :yes:

Arronduke

20th November 2015, 02:57

received some good advise today, I thought I would post it so I actually did what was recommend.

I think a lot of the "problems" people have with gasket's is that they don't prep the surfaces or tighten to the right torque setting, make sure that all of the bolt holes have a nice radius, make sure the threads on the bolts/studs are clean other wise torque settings go out the window.

To be honest on any 2 stroke head bolt's/barrel nut's i don't use a torque wrench, you can "feel" when it's tight enough (20ftlb most is max),and make sure you use the right tool's, you don't use a 1/2" socket wrench for 8mm threads!

Also pay's to check the barrels on a 2 piece setup twin are sat at the same height with a straight edge and put the head on a bit of plate glass make sure it has no gap's with a feeler blade.

Arronduke

4th March 2016, 21:32

What a summer, not a lot done in the shed but now its time to get things back on track.
First up are those dam callipers.... they have been haunting me for ever, now they are viper blasted and painted.
I have used spray cans and are very pleased with the final result.
Colour is Ford Solar gold with a clear coat. Not overly good protection for brake fluid so I will need to be carful when bleeding them, so I have purchased stahlbus bleeders.
Not cheap but hey you get what you pay for, next is stainless pistons and new seals, to be purchased. Total for brakes will be like $800-$1000. The bleeders alone where $300 and the same for the stainless pistons, then add seals and brake pads. I feel sick just thinking about it.

http://www.stahlbus.com/info/en/service/faq-s/bleeder-valves/64-stahlbus-compared-to-other-products

stahlbus goods are 4 x bleeders and a double for the master cylinder, it will be great to be able to bleed the master cylinder, they are always a prick to bleed. Yes I know it can be done and its just a small effort but NO... thats bull shit.
Experance tells me.. buy stahlbus bleeders and if they are as good as the write ups all my bikes will have them.

Arronduke

4th March 2016, 21:53

Product description of the Bleeder valve

Print | Email

100% Brake performance - The stahlbus®-Bleeding System for Bleeding brakes, clutches or any other hydraulic system

What use is the most advanced braking system when the braking performance is strong affected by air in the system and in extreme cases can lead to total failure? Here is our approach to 100% brake power. For the first time the patented stahlbus ® bleeding system allows an air-free filling of hydraulic systems such as brakes and clutches. Improve your brake performance by using our products. The exact way you see here. You can easily bleeding brakes, clutches or any other hydraulic system with one person.

Bleeding brakes

How old is your brake fluid?

Brake fluid is a safety-relevant wear part. This is a fact only a few people are aware of. It should be changed at the latest every two years. Similar to the brake pads and brake disks, the brake fluid contributes essentially to the braking power. Old brake fluid may be compressed and may thus lead to brake failure. New brake fluid maintains the pressure.

The innovative stahlbus® Bleeder Valve allows you to change the brake fluid yourself without assistance and in a very simple way. Clean, absolutely safe and requiring only
a few steps. The innovative aspect of it: The stahlbus® Bleeder Valve tightly seals the relevant brake or clutch during the bleeding process!

The stahlbus® Bleeder Valve was thoroughly tested by the TÜV Rhineland Group (Technical Inspection Agency). With best results. Because the brake fluid is as
decisive for the brake application as are brake pads and brake disks! The most expensive and state-of-the-art braking system does not make any sense if there
is air in the system.

For this reason, our stahlbus® bleed system is also successfully used in motor sports and aviation.

OK.. here is the idea.

As simple as it´s brilliant: stahlbus® principle

Bleeding brakesThe constant opening and closing of conventional bleeder screws during the bleeding brakes process wears the aluminum thread in the cylinder (e.g. of the caliper) in such a way that clearances start to appear with time. At the worst, the cylinder may become defective. Another disadvantage is that the thread of an opened bleeder screw does not seal.

The stahlbus® Bleeder Valve is different, because it consists of two parts with a non-return function. During bleeding brakes, clutches or any other hydraulic system and filling, only the upper part with the integrated O-ring seal is unscrewed. This prevents both air and brake fluid or hydraulic fluid to ingress through the opened thread. In addition, it is no longer necessary to open and close the system synchronously due to the non-return valve. In case of pressure loss the Stahlbus® Bleeder Valve closes independently until the next bleeding pressure is built up.

Thus, the complete system bleeding is achieved within minutes. Single-handedly, without assistance.

Hydraulic systems are easily changed to our stahlbus® bleed system by replacing the former bleeder screw by the stahlbus® bleeder valve. It is inserted into the cylinder once and remains there. Afterwards you can immediately bleeding brakes, clutches or any other hydraulic system with our stahlbus® Bleeder valve.

http://i982.photobucket.com/albums/ae304/Dukeman2/anwendung-bike-220x140-03_zps6v0w4dtg.jpg

http://i982.photobucket.com/albums/ae304/Dukeman2/stahlbus_construction_zpstzpxzgzx.png

Arronduke

4th March 2016, 21:59

don't give me shit but I hate having to click on pictures, so I have added them.

http://i982.photobucket.com/albums/ae304/Dukeman2/brakes_zpshust83ao.jpg

http://i982.photobucket.com/albums/ae304/Dukeman2/DSC02511_zpsgbh3ihg1.jpg

http://i982.photobucket.com/albums/ae304/Dukeman2/DSC02509_zpstwypmfsn.jpg

http://i982.photobucket.com/albums/ae304/Dukeman2/DSC02510_zpsb2zd9pd3.jpg

sugilite

6th March 2016, 09:32

Looking great! This is going to be "The Machine" once it is finished! :Punk:

SVboy

6th March 2016, 11:54

and my fav KB threat roars back into life! But surely there is a better finish for the calipers than paint that brake fluid will possibly lift?

HenryDorsetCase

6th March 2016, 19:19

Where can I get a can of "female valve"?

Arronduke

19th March 2016, 20:23

.. shit paint on calipers, Sir I agree, but I am wanting the bike to look as original as possible even though I have fucked with lots of it. OK only really change a few thing.
What options do I have, paint them original colours and be carful, still might end in tears but hay... I will only have 5 beers before I bleed these brakes.

I was pleased to find complete rebuild kits cheaper than I thought with original Suzuki parts. yes!
progress is still slow.. kids cricket now ended so more time to be had.

Love the brakes stuff so much I ended up fitting them to the GSXR11, WOW, now have to buy more, practiced bleeding the brakes without spillage so ready for he RG.,
All painted parts are soon off to a bake oven to cure then the motor rebuild will begin.

http://i982.photobucket.com/albums/ae304/Dukeman2/rg%20brakes_zps1wempcuy.jpg

Arronduke

19th March 2016, 20:32

Where can I get a can of "female valve"?

Flowers, .. but thinking about it there is a female valve called a "Mouth" seems to fire often.. even small thing set it off.
A dirty plate here, undies on the floor there, used tissue there, next to the PC. .LOL (did I close the page) really HARD to please a women all the time.!
Best to give up and spend all the cash on bikes, in the end the bike looks good, say FA and it is worth more... unlike the older, saggy, hairy companion we married.

Arronduke

3rd April 2016, 19:30

The calipers that have caused me grief.
Done they are, all looking pretty

http://i982.photobucket.com/albums/ae304/Dukeman2/20160319_173450%20Large_zps2jwwtevm.jpg

Lube supplied... not the colour I'm used to..:laugh
All the seals were greased lightly as was the piston, no one likes a dry piston...

http://i982.photobucket.com/albums/ae304/Dukeman2/20160401_224428%20Large_zpsswl9zs5e.jpg

http://i982.photobucket.com/albums/ae304/Dukeman2/20160401_224523%20Large_zps2jmtl8pp.jpg

Bingo... what an effort

http://i982.photobucket.com/albums/ae304/Dukeman2/20160401_225933%20Large_zpsr3wnxpxz.jpg
the old pistons, I tried, yes I did. I was even told... yep they are fine. Noooo Nooo Nooo, could not use them.

http://i982.photobucket.com/albums/ae304/Dukeman2/20160401_230538%20Large_zpsz77ctdkq.jpg

Arronduke

3rd April 2016, 19:34

Oh and that fancy valve... now that makes my heart happy.

http://i982.photobucket.com/albums/ae304/Dukeman2/20160401_232002%20Large_zpsid8qbrhc.jpg

http://i982.photobucket.com/albums/ae304/Dukeman2/20160403_173223%20Large_zps4jrz9cvx.jpg

Notice the front of he fork, some thing is missing, fork are about to come out as I have drained the oil, need to check everything and add new oil.

Arronduke

14th April 2016, 20:28

Rear caliper re-kited with new seals all good to go.
Piston like new, so I'm not replacing that.. everything else done.
Don't like the look of the carrier, might have to have the women clean that!
Looks dirty, lets not go there...

http://i982.photobucket.com/albums/ae304/Dukeman2/20160403_173338%20Large_zpsdnoqnjz0.jpg

Arronduke

14th April 2016, 21:10

What is this.... its a rear height adjuster. After a little research on how to make an RG5 handle, I found out that you want to lift the rear, especially with 17ich running gear.
RG500 Strut

http://i982.photobucket.com/albums/ae304/Dukeman2/adjuster_zps7wgirxpx.jpg

The LG RG500 Strut is a high quality piece that has been instrumental in making my Gammas more enjoyable to ride.

http://i982.photobucket.com/albums/ae304/Dukeman2/strut_01_zpst2ip6u62.png
http://i982.photobucket.com/albums/ae304/Dukeman2/strut_02_zpsjbfoa4qh.png

Stock Gammas can be perceived as having heavier handling than the light weight of the machine would imply. This is aggravated with the installation of wider wheels and tires, necessitating the alteration of the chassis geometry to compensate. Raising the forks up to 20mm in the clamps and installing an adjustable strut makes it possible to alter the steering head angle from 25.1dg (stock) to mid 23dg with about 98mm of trail (down from 110mm stock). These are very contemporary numbers and very effective.

This image shows the black Quad O-Ring seals used to insure a long service life for the spherical bearings.

RG500 Strut The light colored areas shown on the RG500 strut threads are Delrin (Acetal Homopolymer) inserts. This prevents the adjuster from turning in service, thus eliminating locknuts. Ride height adjustment is done by reaching in with a single wrench and turning the center section of the strut.

RG500 Strut Just for reference, here is the stock RG500 strut.

RG500 Strut
Installed and ready to ride, the LG strut is mechanical art with a purpose. It personalized the handling of my bikes to suit my preference.

As an added bonus, stability at speed is enhanced. Properly adjusted, this part will help your Gamma turn in easier and quicker while also providing more stability at the redline in top gear.

The specially sealed spherical bearings and robust construction have lasted for many miles of rapid riding.

OK... not obviously written by me, one I cant pronounce these words, or spell them.

http://i982.photobucket.com/albums/ae304/Dukeman2/strut_zpsfqrv6epn.jpg
http://i982.photobucket.com/albums/ae304/Dukeman2/strut_03_zpsddecsylj.jpg
http://i982.photobucket.com/albums/ae304/Dukeman2/strut_04_zps1wdl63sf.jpg

Ok remember this picture...
http://i982.photobucket.com/albums/ae304/Dukeman2/adjuster_zps7wgirxpx.jpg
$324 but there are no great seals, nothing like the original. That's the price after all tax.

Check out this sucker.... yep the beans.
Done properly.

http://i982.photobucket.com/albums/ae304/Dukeman2/20160413_185057%20Large_zpswnlk9ld9.jpg

$265 USD ... add tax = $369
Which one will you buy?

Arronduke

14th April 2016, 21:16

http://i982.photobucket.com/albums/ae304/Dukeman2/20160410_171809%20Large_zpsdcyiycjm.jpg
Gave the cranks a spin, I hate that they sit, a little oil ..lol, heaps of oil makes sure there good to go.

Arronduke

14th April 2016, 21:20

Damage done.

http://i982.photobucket.com/albums/ae304/Dukeman2/20160414_172741%20Large_zpsvybwiecm.jpg

Standard..

Arronduke

14th April 2016, 21:28

http://i982.photobucket.com/albums/ae304/Dukeman2/20160414_174408%20Large_zpssprsrhka.jpg

Like buying the wife a lift, cost heaps. You have no idea about the result. And.... really its an old pig, a lift ant going to make it perform like a sub, 20 yr old.. .

You spend a lot of money at one end and the other end is still fucked.

Next up.. forks.

http://i982.photobucket.com/albums/ae304/Dukeman2/20160410_162407%20Large_zps0jxj53wx.jpg

The guts..

Arronduke

14th April 2016, 21:35

http://i982.photobucket.com/albums/ae304/Dukeman2/20160410_162407%20Large_zps0jxj53wx.jpg

New gasket for the blocked off anti dive.
Stripped for an inspection, hell I would not buy a women know with out the, strip inspection.
You have to make sure its right.

sugilite

14th April 2016, 21:42

Sweet work going on there Mr Duke.
Loving the updates!!!

Drew

15th April 2016, 07:22

Don't blindly wind the rear ride height up. Swingarm geometry is a fickle thing and can create unexpected results when altered.

Small changes at a time, keep notes of everything you do.

HenryDorsetCase

15th April 2016, 08:03

Don't blindly wind the rear ride height up. Swingarm geometry is a fickle thing and can create unexpected results when altered.

Small changes at a time, keep notes of everything you do.

Fuck that, all or nothing! Death or glory!

This is my favourite bike, and favourite thread, on KB. I also like the ESE one but I dont understand what those guys are talking about. I just go for the pretty pictures and videos

sil3nt

15th April 2016, 12:17

I guess you can adjust the ride height without removing it from the bike?

malcy25

15th April 2016, 12:17

This is my favourite bike, and favourite thread, on KB. I also like the ESE one but I dont understand what those guys are talking about. I just go for the pretty pictures and videos

same same! Great fun watching

Reckless

15th April 2016, 20:48

Enjoy the thread too :Punk:
You certainly do things properly and its a pleasure to watch :)

Arronduke

16th April 2016, 18:46

I love the reply's.... thanks

Regarding the lifting strut, I have to say that I was shocked at how much the ass lifted with a few turns. I was not expecting that.
Yes it can be adjusted easy in the bike so that will be good.

I wish I could buy a thing this simple to lift the wife ass so simply... gravity is a bustard. Its a common theme ... old bastard and hot misses. It seems in order to achieve such a thing you need huge amounts of money. Who would have thought a hot ass would cost so much! and the older you get the more expensive that hot ass costs!

Fork oil is on order, manual says 97mm from top of fork, 15w. Rick Lance says 95mm and 20w. I guess I will do what I am told, seems to have worked for the last 20yrs being married. So why fuck up a good formula.

jobs...

Forks done... soon
Barrels being bored... yep that is great news, so exciting that I forgot to tell the misses... just put it on the credit card and hope for the best.
Once barrels back, paint them.
And the bake all the painted bits, of wish there are many.
Start to assemble motor.. yea .. cant wait.
Rebuild gearbox with new bits
Rebuild carbs
Drink beer 24/7 and were good to go.

I just need to work out the piston, cylinder clearance so Franklin Engineering can do the job, there is a dude Keith that works there and with one look at the barrels said..."they are RG500"
I was seriously impressed, I have full confidence that they will do a great job, I have had other thing done there and always a top job.
Not sure on cost, but a rebore x 4 cylinders and chamfer of 8 ports each cylinder (FROM MEMORY) is time consuming. Wife might need a second job to pay for this and it might mean her stretching out on a pole... or selling used undies on line... $20 a pair... let me know how many you want and how used you want them!

Pumba

16th April 2016, 20:56

Arronduke

23rd April 2016, 19:24

Mate I am worried that all the expense of building the bike is cutting into your beer budget; because your posts seem a shit load more coherent than they used to be.

Best you disclose to the Mrs how much you have spent (figures from the last week should be enough, don't be stupid enough to give her the total to date) because a few solid concussions should put you right back on track.

Pam ba - ba - ba, I had to get suitably adjusted to launch a reply! So I have, home alone, Neil Young on 2nd screen and a beer in my hand, OH and that what's for dinner feeling... f#ck I have to make it!
But more importantly I needed to reply to the slight, mark, dent, wound that you have inflicted to onener.

Arronduke

23rd April 2016, 19:46

Pamba, the truth is , age. If I am awake at 3am it because I need a piss.:(

Arronduke

28th April 2016, 21:44

Yes yes yes... time to pour a beer, yep.
Check out the picture, this little job has been on the horizon for a while. Just needed to steel the milk money and its done.

http://i982.photobucket.com/albums/ae304/Dukeman2/20160422_212453%20Large_zpsjgr0oa58.jpg

Barrels are now bored first size over size - 0.5mm To be honest they were so close to being within in spec it was not funny but bored they are. And a fantastic job done by Franklin Engineering. I was impressed the dude Keith took one look and said... RG500 barrels.

These puppies have eight ports each, so that's four cylinders bored and honed, eight ports chamfered for $661. Service and quality second to none.
http://i982.photobucket.com/albums/ae304/Dukeman2/20160422_212244%20Large_zpsyv0wswph.jpg

http://i982.photobucket.com/albums/ae304/Dukeman2/20160425_172720%20Large_zpsuthxp22l.jpg
That's a great hole! and not a hair to be seen!

http://i982.photobucket.com/albums/ae304/Dukeman2/20160425_174400%20Large_zps9zdplqm3.jpg
All tapped up for a fake tan... cant get the tan spray in the hole now can we!
Yes this is cylinder one, each piston and cylinder have been machine as a pair, getting pissed and mixing them up would not be advisable.

http://i982.photobucket.com/albums/ae304/Dukeman2/20160425_174350%20Large_zpsqquugbfe.jpg

Remember them forks, well I could not help myself, I had to pull them apart further to see how they had been modified, and they have with extra holes for the dampening.
Good old Rick Lance recommended 95mm / 20w oil. The original is 97mm / 15w.
Long story short, job done and all back together.
http://i982.photobucket.com/albums/ae304/Dukeman2/20160423_145419%20Large_zps4nutardk.jpg
Boxes of parts that have been painted, once the barrels have their tan coating then off to a rather large oven for baking. Then the engine rebuild will start!
http://i982.photobucket.com/albums/ae304/Dukeman2/20160422_212332%20Large_zpsqs1nxakv.jpg

Arronduke

28th April 2016, 22:09

Front end looking better with some finishing touches.
http://i982.photobucket.com/albums/ae304/Dukeman2/20160428_213326%20Large_zpslfo1mhou.jpg

http://i982.photobucket.com/albums/ae304/Dukeman2/20160428_213201%20Large_zpsjbfwcdgl.jpg

Tidied up the rear with a few bolts. Still got some cleaning to do!
http://i982.photobucket.com/albums/ae304/Dukeman2/20160428_213252%20Large_zpsyojh5zy2.jpg

http://i982.photobucket.com/albums/ae304/Dukeman2/20160428_213235%20Large_zps8srqoisz.jpg
Rear brake is next, parts off being plated, body already powder coated and seal kit on order.
Shame one cant do such things to ones other half.... Oh yes we have been there and it never ends well.
And yes... some washing will be done.

http://i982.photobucket.com/albums/ae304/Dukeman2/20160428_213307%20Large_zps1pei62ai.jpg
Yes black plating done, F/knows were that washer went for the rear brake, new one on order. There may have been heathens in my shed, stealing washers just to piss me off.
Might have to set some traps, sister in law was not happy when she found out I was teaching her 15yr old how to make KN03 (potassium nitrate) / rockets and bombs last week in the school holidays. Cant see the issue my 10yr old knows the mixture off by heart.

SVboy

29th April 2016, 07:38

Almost on the home run!

malcy25

2nd May 2016, 12:30

HenryDorsetCase

8th May 2016, 17:52

sister in law was not happy when she found out I was teaching her 15yr old how to make KN03 (potassium nitrate) / rockets and bombs last week in the school holidays. Cant see the issue my 10yr old knows the mixture off by heart.

Can I come live at your house?

because that shit sounds like FUN.

Oh yeah, with the forks: if the Anti Dive is blocked off, and someone has fucked with them, why not go the whole hog with some Racetech Gold Valves or equivalent? Esp since you have done the rear (so to speak)?

Arronduke

13th May 2016, 22:10

Can I come live at your house?

because that shit sounds like FUN.

Oh yeah, with the forks: if the Anti Dive is blocked off, and someone has fucked with them, why not go the whole hog with some Racetech Gold Valves or equivalent? Esp since you have done the rear (so to speak)?

Sure you can... do you swallow?
If you were able to read, which obviously you cant you will see that, yes the forks have all the gold shit!

Today was a special day, we all like to bake and bake today I did.
100c for 1hr and 2hrs cooling... http://i982.photobucket.com/albums/ae304/Dukeman2/IMG_4081%20Large_zpsthfassmq.jpg

Hell you could bake quite a cake in this oven...

Got home and had to open a beer, any why would you not, its been how long since I seen these bits? Crank case mounted on engine build stand cause I can.
Gearbox rebuild time.
Now this needs to be done before beer 6... we need to make sure everything is kept in order. Ellis Moore gearbox parts are to be installed. taller 1st gear to close the rather large gap between 1st and 2nd and stronger 6th gear. So all up... new 1st gear, 2nd gear and 6th gear. rather a mind fuck all this gear shit so very careful to put each part in to its own bag. there will not be a fuck up here. All completed by beer 8..lol...

http://i982.photobucket.com/albums/ae304/Dukeman2/20160513_165729%20Large_zpsmrsypluw.jpg

Yep the world famous cassette gearbox, able to be removed in 15min to change ratio for individual race tracks... yea right, real story is quick removal to repair!

http://i982.photobucket.com/albums/ae304/Dukeman2/20160513_170447%20Large_zpsqno3inkg.jpg

See that bearing top left... yep that fucker.. well that was a basterd to remove, ali casing so small, heat and tap. all ended well.
http://i982.photobucket.com/albums/ae304/Dukeman2/20160513_174613%20Large_zpsapmvn3lp.jpg

Arronduke

13th May 2016, 22:24

3 x new gears.
http://i982.photobucket.com/albums/ae304/Dukeman2/20160513_175605%20Large_zpsvjjc3ivk.jpg

new 6th gear, notice the better engagement doggy things! Even the metal looks better quality.

This here is second gear, again engineering upgrades. Right I will say my guess but some smart ass is sure to correct me, I've noticed that... smart asses that know more than me. If your one than please comment! Best to know the truth. But my guess the up graded 2nd rear is strength and then that word again, engagement.

Arronduke

18th May 2016, 20:02

[QUOTE=HenryDorsetCase;1130969405]Can I come live at your house?

Henry... I think an apology is due, I was trying to be funny but on review it did not come a cross as such.. sorry dude!

Drew

18th May 2016, 20:04

Henry... I think an apology is due, I was trying to be funny but on review it did not come a cross as such.. sorry dude!Lol, priceless.

Arronduke

18th May 2016, 20:34

Don't ever let it known that I did such a thing... NEVER apologise to a women, after all its there fault that we have to work so hard! If it was not for the women's lib, lefties, man haters. Women would still be at home making sure our beer was cold. Now they have to work, raise kids and pay for my bike building addiction while I just play in the shed it makes me sad. I sure would rather work 60hrs a week and be the... wait until your dad get home dad. LOL.

Thanks to them, now I get to do FA, while that wife works her ass off, cooks dinner and earns a shit load. I love evolution.

Anyway... gears and how they have changed.
http://i982.photobucket.com/albums/ae304/Dukeman2/20160513_182754%20Large_zpstvmkrdhy.jpg

http://i982.photobucket.com/albums/ae304/Dukeman2/20160513_183146%20Large_zps4gpejbvr.jpg

http://i982.photobucket.com/albums/ae304/Dukeman2/20160513_173310%20Large_zpsqgqqirqn.jpg

http://i982.photobucket.com/albums/ae304/Dukeman2/20160513_170447%20Large_zpsqno3inkg.jpg

http://i982.photobucket.com/albums/ae304/Dukeman2/20160513_170429%20Large_zpsjtf9htqh.jpg

Arronduke

20th May 2016, 20:59

Been working on this gearbox, don't know about you but it looks dam scary to me.
Ive been very carful to bag each part, shaft etc but still its a nightmare.
Priced up parts to finish the rebuild... hell all the major bits are done so its just bearings and seal, yep they should cost FA... $1000 for rigy didgy bits. All Suzuki.
Bugger that I say, first off is bearings, off I go to the bearing shop... dam they are good.

http://i982.photobucket.com/albums/ae304/Dukeman2/20160520_193642%20Large_zpsirpk2ufx.jpg
This lot cost $69 bucks. Now that saves some dollars. Seals I will not change, must be the real thing.

http://i982.photobucket.com/albums/ae304/Dukeman2/20160520_195146%20Large_zpsgg6i8ezx.jpg
Might be a good idea to remove the seal, other wise its the same bearing.

http://i982.photobucket.com/albums/ae304/Dukeman2/20160520_195418%20Large_zpsthlatltw.jpg

Now this fucker bearing is pissing me off, struggling to find the part number, it has a pin so it will be a real Suzuki bearing.
http://i982.photobucket.com/albums/ae304/Dukeman2/20160520_195024%20Large_zpsx3kbttkd.jpg
Once I have sorted the part number I will add it to the list of after market bearings.
http://i982.photobucket.com/albums/ae304/Dukeman2/20160520_194755%20Large_zpstuybj6zq.jpg
yep the one between numbers three.

Arronduke

20th May 2016, 21:03

Henry... I miss you!

caseye

20th May 2016, 21:18

Henry... I miss you!

He'll get over it, now get building agin , hurry up!

SVboy

21st May 2016, 08:44

That looks like a pretty specialised bearing all right.

Arronduke

27th May 2016, 21:34

Caseye, you sound like my misses.. most likely your much uglier, stink, have acne scars and a nervous twitch, and that's just your nose. While I don't want you hanging around me kids, I do appreciate your input.

Pricing up parts for the engine rebuild, it was good to find out that Colman's prices are the same as US and EURO shops. I've been burnt before buying over seas thinking parts will be cheaper. Not always the case and it seem less now. Price difference was a few dollars each way, some cheaper and some more. Not including postage. So I'm buying NZ. Except bearings which I know are mint to source from Saeco and are mush cheaper, helps to have a 50% discount thanks to work.

I thought while I'm getting prices and a shopping list for the engine rebuild I would clean the carbs.
Great having a good toy..

<a href="http://s982.photobucket.com/user/Dukeman2/media/20160521_161201%20Large_zps0gtnvki0.jpg.html" target="_blank"><img src="http://i982.photobucket.com/albums/ae304/Dukeman2/20160521_161201%20Large_zps0gtnvki0.jpg" border="0" alt=" photo 20160521_161201 Large_zps0gtnvki0.jpg"/></a>

Yep a Ultrasonic cleaner, all carbs are done nice and clean using Yamaha carb clean stuff, I'm sure this stuff is evil it stink max, and will cause you to grow hairs and warts on your nose, best Caseye does not use it as the end result will ensure that he will end up in a circus... on display! Hell it stink that bad I hold my breath getting close. Heat to 40C and 50min vibrating around. Dam pleased the wife does not take this effort, 37C and 2min seems to put her to sleep. She is so lucky.

The carb before.
<a href="http://s982.photobucket.com/user/Dukeman2/media/20160521_161116%20Large_zpscj1tboyv.jpg.html" target="_blank"><img src="http://i982.photobucket.com/albums/ae304/Dukeman2/20160521_161116%20Large_zpscj1tboyv.jpg" border="0" alt=" photo 20160521_161116 Large_zpscj1tboyv.jpg"/></a>

and ready for the dunk, not the drunk just in case you were thinking.
<a href="http://s982.photobucket.com/user/Dukeman2/media/20160521_162427%20Large_zpsxxbfljsh.jpg.html" target="_blank"><img src="http://i982.photobucket.com/albums/ae304/Dukeman2/20160521_162427%20Large_zpsxxbfljsh.jpg" border="0" alt=" photo 20160521_162427 Large_zpsxxbfljsh.jpg"/></a>

Arronduke

27th May 2016, 22:14

Being anal, not taking anal Caseye. I dipped one carb at a time and bagged it. Once the timer was up in to water and then the air gun was put to use. Into the snap lock bag, left open for a week to make sure all the moisture was gone then sealed.

Also all parts that need plating away they go.

<a href="http://s982.photobucket.com/user/Dukeman2/media/20160527_205657%20Large_zpsitkpkha9.jpg.html" target="_blank"><img src="http://i982.photobucket.com/albums/ae304/Dukeman2/20160527_205657%20Large_zpsitkpkha9.jpg" border="0" alt=" photo 20160527_205657 Large_zpsitkpkha9.jpg"/></a>
Looks like the last breath of a poor sole with a bag on their head. The last big draw!

And look how clean these bits are, not an oil drop to be seen, cant wait to put them back together. Rick Lance carb parts will be used, supplied as part of the air filter kit! yea

<a href="http://s982.photobucket.com/user/Dukeman2/media/20160527_205642%20Large_zps5eo39q1a.jpg.html" target="_blank"><img src="http://i982.photobucket.com/albums/ae304/Dukeman2/20160527_205642%20Large_zps5eo39q1a.jpg" border="0" alt=" photo 20160527_205642 Large_zps5eo39q1a.jpg"/></a>

<a href="http://s982.photobucket.com/user/Dukeman2/media/20160527_205642%20Large_zps5eo39q1a.jpg.html" target="_blank"><img src="http://i982.photobucket.com/albums/ae304/Dukeman2/20160527_205642%20Large_zps5eo39q1a.jpg" border="0" alt=" photo 20160527_205642 Large_zps5eo39q1a.jpg"/></a>
Bagged.

And off to be plated.

<a href="http://s982.photobucket.com/user/Dukeman2/media/20160527_205632%20Large_zpshel6k2v8.jpg.html" target="_blank"><img src="http://i982.photobucket.com/albums/ae304/Dukeman2/20160527_205632%20Large_zpshel6k2v8.jpg" border="0" alt=" photo 20160527_205632 Large_zpshel6k2v8.jpg"/></a>
Who the bitch in the glasses, I'm thinking she's not related to Caseye, cause there is not a nose hair to be seen, yepI would give her 2min.

caseye

29th May 2016, 16:07

Who the bitch in the glasses, I'm thinking she's not related to Caseye, cause there is not a nose hair to be seen, yepI would give her 2min.[/QUOTE]

Who'd ya give 2 minutes,lol.
That is some seriously nice work, keep up the pics, please. Call me what you like,I'm hooked, those sonic cleaners are the cats PJ's aye.

Arronduke

17th June 2016, 21:43

http://i982.photobucket.com/albums/ae304/Dukeman2/20160616_164447_zps3qptwgbr.jpg

Christmas time, $1200 notes and all the engine seals, gaskets, bearings and shit I could not get or wanted genuine have turned up. Really struggled to hide this purchase, credit card went boom.
Mental note never give wife access code to bank accounts, how stupid could I be. After much discussion, ok yelling we had to work out how this bill will be paid for.
My ass on the street ant worth FA, I've already confiscated the cash the kids eared selling fruit at the front gate and sold their Lego. Sorry honey while you might be old, your our only hope. If you pick her up be nice after all I still want her home in time to cook breakfast!

A big box, No not what your thinking this one des not leak, a big box, of parts turned up. Bags full of bits that all looking the same. Took me at least 10 beers to break them down in to engine components. To easy to get a million bits and throw them in a bag and think I’ll find them as I use them. Never works, experience tells me such.

So parts are divided in to jobs and groups so I can rebuild sections, bag them and know they are sweet.
Carb parts all plated and ready to go, old now looks new. Wish I could dip the misses.. might need to... but now the would be a money maker!

http://i982.photobucket.com/albums/ae304/Dukeman2/20160617_174712_zps16frybhc.jpg

parts sorted in to bags..

http://i982.photobucket.com/albums/ae304/Dukeman2/20160617_202647_zpsrcnwnzzs.jpg

Man I am looking forward to putting some parts together, about time.

SVboy

19th June 2016, 18:52

You Sir, are a god!

Arronduke

24th June 2016, 21:14

I am loving having parts... better they are genuine Suzuki parts. They just feel better and I know that they are right for the job.
Carbs are all done, new O-rings, filters, seals and Rick lance bits..

Yes the new LG3T float valves, wow what engineering. I wish I was this talented. But we cant be good at everything, beer I can do that!
Instead of the needle with rubber seal we have a ball bearing and a plastic ball. Make sure the float height is 18mm without the gasket.
http://i982.photobucket.com/albums/ae304/Dukeman2/20160623_164850_zpschzn0hzs.jpg
http://i982.photobucket.com/albums/ae304/Dukeman2/20160623_164910_zpsrjsbhcy7.jpg

Two were out, add the 240 mains jets and that the RL kit installed.

One thing that was a fuck up, I sent all the steel bits to be plated. All good until it was time to assemble. The choke and air screw spring length is different.
Now that pissed me off, there was 1mm difference, why?

I was going to just put the springs in but there must have been a reason why, and I hate that. Opinion one was order a spring of each so i can measure, nearly did but then I remembered I have spares and problem solved.

Choke spring is 8.4mm
Air needle is 9.3mm

Why he difference fuck knows but my thought is there must be a reason so I must respect that!

job done.
http://i982.photobucket.com/albums/ae304/Dukeman2/20160624_203616_zpskjaht60s.jpg

Carbs done!

Arronduke

24th June 2016, 21:18

forgot to add.. spares are a wonderful thing.

http://i982.photobucket.com/albums/ae304/Dukeman2/20160624_203642_zpsbmjghfmv.jpg

http://i982.photobucket.com/albums/ae304/Dukeman2/20160624_203653_zpskslomxfz.jpg

Arronduke

30th June 2016, 21:35

Shit, the forks have to come out. again. The fork set up I purchased had simple aluminium plates and gasket paper and gasket goo to seal off the now unused fork dampening thingy. Yes I could just throw them in the bin but wanting to make the bike look original with purposeful modification they had to stay.

When I got the fork setup they leaked at this point, so being a good solder I removed these dam forks and redid them with gasket sealant and new gasket purposely made. Add fork oil 20W , yep 20wat as recommended by Rick L and the f#cking thing still leak... Not happy.

So another $100 USD I have these, the proper McCoy! Asshole things will not leak now, and no gasket gooy shit or paper to be seen.!

http://i982.photobucket.com/albums/ae304/Dukeman2/20160630_161143%20Large_zpstfwijkhv.jpg
Now the job will be done properly...

I'm building components and then putting them in bags ready for the big assembly.
First off was the water pump assembly.

A couple of points worth stating.
1) how to install the water pump mechanical seal, and yes the blue stuff is the sealant.. Suzuki bond 1207B.. the old version did not have this.
2) Make sure you press this in squarely, I used a vice and a socket of which there are multiple sizes in each socket set perfect for the job.
3) The manual says, make sure the oil seal goes in the right way but fails to tell or show which way the dam thing should be installed.
4) Make sure you grease / lubricate the oil seal lips, like you would a good pussy be for installing the rod!

http://i982.photobucket.com/albums/ae304/Dukeman2/20160625_162131%20Large_zpsupuzw5z4.jpg
Piece of wood and the back and front and slowly tighten the vice, water pump mechanical seal installed, square!

Arronduke

30th June 2016, 21:49

Ah, just like that dam manual, I did not show which way that dam oil seal in the water pump MUST go, fuck this up and its all bad.

Think of an the outside engine oil seal, same here, which side is the oil on?

http://i982.photobucket.com/albums/ae304/Dukeman2/20160630_171505%20Large_zpsxx6xg312.jpg
Yep insert oil seal this way like any other oil seal to keep the oil in the gearbox.
Bearing goes on top of this.

Arronduke

30th June 2016, 21:58

Here is an interesting point I did not know.. there is a threaded hole on the bottom right picture of the impala housing which should be removed periodically to make sure the water seal, oil seal are working as they should.
Remove this bolt and if water comes out, the water seal is leaking and if oil comes out the oil seal is leaking. Who the fuck knew that! Shows what a little reading does.

Obviously no bolt in it now but you get the point, I hope.

http://i982.photobucket.com/albums/ae304/Dukeman2/20160625_155619%20Large_zpsffjuvuzn.jpg
yep that little hole

Arronduke

30th June 2016, 22:06

Oh and another seal not show easily which way it goes.\\
http://i982.photobucket.com/albums/ae304/Dukeman2/20160625_164701%20Large_zpshubszdcy.jpg
eaiher turn it over or tell it to turn over, depends on who's boss.
http://i982.photobucket.com/albums/ae304/Dukeman2/20160625_164655%20Large_zpsnanvlfym.jpg
get these few thing right and there will not be a leak, unlike that twat close to you at night, which can have flaps the size of banana skins and still leak :Oi:

Arronduke

30th June 2016, 22:16

And to finish up tonights edition, all donations appreciated. I have stated on the gearbox.
First off install bearings.

They are a interference fit, so do I get out a big hammer and 5 beers? Sounds reasonable. actually a good idea?
No put the bearings in the freezer, drink 5 beers, while waiting a couple of hours, in their plastic bags obviously. Then heat the housing with a heat gun until warm over a 10min period letting the temp equalise.
The bearing will just drop in, magic.

Bearing shrinks, housing expands and bingo no issue.
Not a hammer in sight.

http://i982.photobucket.com/albums/ae304/Dukeman2/20160630_162232%20Large_zpslumg26gh.jpg

Drew

1st July 2016, 06:24

So, how did ya figure out which way was correct for the seals?

Arronduke

3rd July 2016, 17:46

Drew think of the crank drive shaft engine seal where you chain goes, or any seal the you can see on the outside of the engine.
You all ways see the flat side, the lip side is inside.

The water pump area is design to keep oil in one side and water out the other side, so based on the fact we need to keep oil in, the lip side is oil side.
So basically all ways have the lip side oil side.

Drew

3rd July 2016, 18:40

Ah, so they're not some mongrel thing where it's not obvious.

pritch

6th July 2016, 10:57

A friend of mine worked in engine reconditioning and he once told me that most of the restoration jobs on classic/vintage cars and bikes that he saw were done on the cheap rather than done right. It's a pity he's not here to see what you're doing.

Arronduke

22nd July 2016, 20:55

Arronduke

22nd July 2016, 21:58

With all rebuilds its two steps forward and three back, all the best planning and lack of planning happens.

As I started to rebuild the gear box... well fuck me the gear did not fit, for 5min I thought all my carful planning was shit. What have I done wrong? then it dawned on my something is not right. Drink beer and sulk.
Yep the bronze bush is missing. Shit gear has only being sitting in my parts box for a couple of years... Contacted Moore Performance Engineering and sent the gear back to the UK to have the bronze bush fitted. yes could have done it in NZ but I wanted it done by the manufacture. Don't need a mind fuck if something goes bad and I need to have THAT conversation.
Its now on it way back to NZ.

http://i982.photobucket.com/albums/ae304/Dukeman2/20160513_183150%20Large_zpsyvfpwnmb.jpg

Next was the water pump reassemble, started to fit the engine bolts. I thought I would not get anal and just use them as is. how they came off. Nope. They looked terrible, my mind raced, beer did not help and the decision was made to degrease them in my ultrasonic cleaner, wire brush them with the drill press and then send them to Napier for replanting, black. dam hard to find anyone to plate black now. Oh and by the way, If you send crap, you get crap. Send clean stuff and it comes back like new.

http://i982.photobucket.com/albums/ae304/Dukeman2/20160721_164108%20Large_zpsw9nh661j.jpg

Ohhhh now for the real piss off. The fork blanks for the anti dive came with aluminium plates and a gasket, they leaked. So I disassembled the whole front end and made new gaskets. Proper ones, I thought.
Bolted everything back up, lock tight etc and bugger me they leak again. Not like last time, just a real small weep, like an abused wife that should have cooked eggs. I degreased, new gasket and fitted the anti dive units and waited, run my finger under them and, yep there was a smear of oil. Just a smear, ask you wife if a smear means anything and i guess is you will not get eggs. We know how to fix, use proper stuff.

http://i982.photobucket.com/albums/ae304/Dukeman2/20160722_193556%20Large_zps2zzyfnwr.jpg

Askor

14th November 2016, 21:12

moar updatezzzzz

Arronduke

29th November 2016, 02:11

Between trying to rewire parts of my Katana and kids cricket, which by the way takes so much time that had I known the boys would have been playing softball or tennis... and waiting for bits that I have not ordered yet cause I am too lazy there has been slow progress.

Got the engine bolts re plated the same colour as the originals. I tell you what it is harder than you think to find a place that does black, or black with a green ting as used on 80’s Jap bikes.

http://i982.photobucket.com/albums/ae304/Dukeman2/20161125_154827%20Large_zpsha0oujhw.jpg

Then I lost that F#cken washer and could not be bothered ordering it!
Yep number 6.

http://i982.photobucket.com/albums/ae304/Dukeman2/20161111_180008_zpsfzo6xikw.jpg

Throw in some bearings... put them in the freezer for a few hours (open beer) and heat the engine cases with a heat gun and your good to go, just throw the bearings in and your done. Open more beer.

http://i982.photobucket.com/albums/ae304/Dukeman2/20161114_204833%20Large_zpsdydflws6.jpg

http://i982.photobucket.com/albums/ae304/Dukeman2/20161114_204849%20Large_zpskjuscmdd.jpg
All the good things to use when assembling an engine... beer, big steel hammer and a crowbar. Yea yea I have hidden the steel hammer. But Loctite where needed and assembly paste on all moving parts. Grease on the seals and soft hammer ONLY when something does not fit.. always have minimum of 6 beers before using the soft hammer.

Arronduke

29th November 2016, 02:24

http://i982.photobucket.com/albums/ae304/Dukeman2/20161114_204903%20Large_zpsaqqlybwf.jpg
I like it when bits fit as they should, look nice and new.

Getting ready to bolt in the gearbox. It all turns over and I can spin through the gears. So to me that's a positive....
http://i982.photobucket.com/albums/ae304/Dukeman2/20161127_181040%20Large_zpskq3wgamh.jpg

Decided to add a small turbo..
http://i982.photobucket.com/albums/ae304/Dukeman2/20161127_181107%20Large_zpshf0spgkl.jpg

Drew

29th November 2016, 05:35

There's a really tidy RG500 for sale up here in Wellington. Oh how I wish I could afford it.

Arronduke

7th December 2016, 19:00

Drew how much are they asking?

Arronduke

7th December 2016, 20:52

http://i982.photobucket.com/albums/ae304/Dukeman2/20161207_184856%20Large_zps18mspnuu.jpg

This is a very, I mean very good diagram of the gearbox component order.
I cant tell you how many times I studies this when reassembling the gearbox shafts. But I had ONE washer out and the gearbox locked up when torqueing down the 8mm nuts.
In the end it was the kick starter... and oil pump washer. Remember the one I could not find well that bastard was stuck to the engine casing when I removed the gearbox after testing. Could not find that fucker and ordered a new one.
So now there where two.... any how problem solved and bingo gearbox is perfect, new gears, with new ratios installed.

No idea who did it but they have saved many hours of mind fucking when you are double checking!

And Yes I have two torque wrenches... and a cooking wench, they are a must.

Drew

8th December 2016, 05:25

Drew how much are they asking?

$14k. I'd pay it if I had it.

Arronduke

8th December 2016, 19:13

Ill add this picture again as the first one was not the best.
Normally I would not bother but this picture is worth it!

http://i982.photobucket.com/albums/ae304/Dukeman2/post-23149-0-04559600-1473196500_zps1uoe350n.jpg

Arronduke

8th December 2016, 19:14

$14k. I'd pay it if I had it.

To much cash for me also... brought mine for $6500 and I was told I paid tooo much!

Arronduke

20th December 2016, 20:04

Tools, I love tools.
I have so many tool that my tool box is full. Why you ask? simple... buy quality and I did not in my younger days. So I buy better quality tool now as needed, and I cant bring my self to throw the older stuff out.
Saying that it means better than Chink tools that are good for about 5min. I now buy as good as I can afford that will last a life time.

I try and buy tools that will last years... but I cant afford the top of the line stuff.... did I mention wife has a horse.. that fucks all spending. Get a horse and get a divorce. NEVER alloy your wife to get a horse... what was I drinking!

http://i982.photobucket.com/albums/ae304/Dukeman2/20161207_204147%20Large_zpsnosrkyxh.jpg

Not the best torque wrenches on the market, they get used a lot but, well worth the investment. To be honest some bolts I will tighten by hand, you can feel how tight they are, like a good pussy.
Then I will finish it off with the torque wrench to check carefully. Most of the time I'm close to spot on. Reason being is I'm paranoid of over tighting bolts in to aluminium. The results ant good. Lock tight is good used carefully on bolts as indicated in the manual.

beer time.!

husaberg

20th December 2016, 20:15

did I mention wife has a horse.. that fucks all spending. Get a horse and get a divorce. NEVER alloy your wife to get a horse... what was I drinking!

I have never considered that, but at what temp do you alloy your mrs (Sorry)
Consider yourself lucky The neighbours have just spent 15G on their horses sore leg. Yet It still has a sore leg.
The 15G is about the same as i will sell my cattle for each year, as well as filling my freezer, they also eat the same amount of grass as the horse.

PS Great thread Aaron, i always look forward to your updates.

Arronduke

20th December 2016, 20:27

Oil pump cleaned up and installed, all my reading tell me that these things are not rebuild and do not fail. So based on that its been cleaned up and installed.
Yes it has the Yamaha check valves, used on snow machines from memory and using model airplane fuel line so you can see the oil flow, now that is worth the effort.

part number # Yamaha external check valve, in the oil line, Part number is 8ch-1316a-00-00
http://www.flickr.co...uki/3441627149/

This will stop the common problem of 2 stroke oil flowing into the carbs when sitting.

http://i982.photobucket.com/albums/ae304/Dukeman2/20161208_213828%20Large_zpsdhimk0an.jpg

Now what's next on the assemble list.. beer after all is Tuesday before Christmas. Why the fuck the wife cant understand that don't know!, kids are at grandparents and we should be taking advantage of such times... beer, bikes and stereo or ..... 5mins and lights out!

Arronduke

20th December 2016, 20:47

Time to install the cranks, these puppies have been soaking in engine oil in bags since they were built, a friend add a crank built for a Kat and the crank went dry and had a good old rust spot in a bearing and bingo, crank failure. What a waste of money. No way was that going to happen to me. So after draining the oil off the cranks in they went. Timed as per the manual. Line up the dots. Even pissed a fool can achieve this so I had a go and checked the results twice plus!! to make sure there was NO room for an error.

http://i982.photobucket.com/albums/ae304/Dukeman2/20161216_172711%20Large_zpsgbljc4st.jpg

http://i982.photobucket.com/albums/ae304/Dukeman2/20161216_172720%20Large_zpsllg140t1.jpg

http://i982.photobucket.com/albums/ae304/Dukeman2/20161216_172734%20Large_zpsc9200u2e.jpg

Notice the crank seals, all new and looking nicely spaced, no rub on the crank.

Arronduke

20th December 2016, 21:13

Ok what's next, clutch and I have paid top dollar... Horse do not mention horse. Stupid thing had a cold, runny nose and bingo $1300 gone. WTF. My nose runs and I'm lucky to have a aspirin brought my way.
Its called Flicker and I call it Fucker, I say no more.

Back to clutch, I'm installing the Rick Lance clutch upgrade kit, what a great kit. Remove the wire clip and throw away the bits and install the Rick lance clutch kit.

http://i982.photobucket.com/albums/ae304/Dukeman2/20161218_162733%20Large_zps2qil3yyr.jpg

If your interested in how this clutch setup works, go to the Lance Gamma site and all the info is there, sooo much detail and install info a women could do it.
ok LETS not be stupid but nothing hard here.

jafagsx250

21st December 2016, 05:26

I have never considered that, but at what temp do you alloy your mrs (Sorry)
Consider yourself lucky The neighbours have just spent 15G on their horses sore leg. Yet It still has a sore leg.
The 15G is about the same as i will sell my cattle for each year, as well as filling my freezer, they also eat the same amount of grass as the horse.

PS Great thread Aaron, i always look forward to your updates.

How many cows does 15 grand get you?

Awesome build too

husaberg

21st December 2016, 17:28

How many cows does 15 grand get you?

Awesome build too

Cows are for breeding or Milking, Steers and heifers are for eating.

The cattle are brought as calves and go to the works as R2's
I don't farm anymore, i only have a lifestyle block/Motorbike grasstrack and TT course now.

jafagsx250

21st December 2016, 19:50

Cows are for breeding or Milking, Steers and heifers are for eating.

The cattle are brought as calves and go to the works as R2's
I don't farm anymore, i only have a lifestyle block/Motorbike grasstrack and TT course now.

I know that cows are bred and raised for different reasons.

Would a grand buy you a cow?

SVboy

21st December 2016, 21:20

And Christmas comes early to KB! Yay!

speights_bud

22nd December 2016, 08:31

I know that cows are bred and raised for different reasons.

Would a grand buy you a cow?

It'd probably buy you a little over half a good black Angus steer I think (I grew up farming and the old mans still in it). I think he's getting $1800 odd per beast on a good day... I could be fucking miles out but that is the number which rings a bell to me....

Arronduke

22nd December 2016, 13:40

Would a grand buy you a cow?

Fuck Yea..... I got my cow for much less than that, and this cow can cook and clean.
Not sure whats she is worth as an R2?

jafagsx250

22nd December 2016, 18:30

Fuck Yea..... I got my cow for much less than that, and this cow can cook and clean.
Not sure whats she is worth as an R2?

Bargain of the century!

Did you buy the cow from Thailand?

Sent from my GT-I9506 using Tapatalk

Arronduke

22nd December 2016, 21:19

husaberg

22nd December 2016, 21:47

Na a local cow from up north... with a bit of training they turned out all right.

You just have to be selective as it can go wrong very quickly. Them Thai cows might look good but their suitcases are very big. You get home and say what the Fuck is in this thing and out pops their mother, sister and the rest are on there way using your credit card. And I'm told, they sit down and don't get up... these cow do not lay down any more only sit and moooo constantly!
Better the cow you know!

Speaking of leather what are you doing with the seat and bodywork? Schwantz Pepsi
https://s-media-cache-ak0.pinimg.com/originals/20/6a/fb/206afb5b34805f1a03802c3674f149d7.jpg
https://s-media-cache-ak0.pinimg.com/736x/33/2f/14/332f14293662d82ff16174c401334354.jpg

jafagsx250

23rd December 2016, 06:31

Na a local cow from up north... with a bit of training they turned out all right.

You just have to be selective as it can go wrong very quickly. Them Thai cows might look good but their suitcases are very big. You get home and say what the Fuck is in this thing and out pops their mother, sister and the rest are on there way using your credit card. And I'm told, they sit down and don't get up... these cow do not lay down any more only sit and moooo constantly!
Better the cow you know!

Not very many bulls up north compared to cows.

Do you speak from experience haha?

I know a couple of people who got a mail order and they went as expected. Terribly. I'll stop going off topic now.

Arronduke

21st February 2017, 20:31

Like always it’s been busy, Christmas and New Year meant little was done and what I did do, I could not be bothered posting. Something to do with holiday time.
This is my first full week back at work, not good. Its only Tuesday and I’m drinking beer. Most days by 3pm a beer is open at camp and the night follows from there. BUT, I’m no longer on holiday and yes I have done a few things beside get and all over tan..!

Last visit to this site and I was looking to close the crank cases, simple you would say, but first thing is the clutch needs to go in.. . I installed the new clutch, as the instructions say I needed to separate the backing plate and install as per the Rick Lance instructions. What a kit. Can’t wait to see how this new clutch works. Soak everything in engine oil over night and good to go.

http://i982.photobucket.com/albums/ae304/Dukeman2/20161222_194402_zps57nqy7gg.jpg

http://i982.photobucket.com/albums/ae304/Dukeman2/20161218_162733%20Large_zps2qil3yyr.jpg

http://i982.photobucket.com/albums/ae304/Dukeman2/20161222_194414_zpsrjeach8p.jpg

http://i982.photobucket.com/albums/ae304/Dukeman2/20161222_200936_zpskdmj8dnh.jpg

Arronduke

21st February 2017, 20:58

Now it was time to close the crank cases, buy a tube of silican put it in a holder and apply thickly.

BUT before we do that, make sure you know which bolts go where, they are differnt lenghts that are made to fu#k you over.
This helped heaps.

http://i982.photobucket.com/albums/ae304/Dukeman2/20170119_180747_zpsjerlpafh.jpg

then if your as anal as me, not liking anal as many KB people you make sure your spot on...
Can I add dont you love the plated bolts. Very hard to have done and only one place that does this colour that I could find and that was in Gisborne.

http://i982.photobucket.com/albums/ae304/Dukeman2/20170119_180702_zpsqndjxbsg.jpg

Next be supper anal and lay everything out so you cant fu#k it up... obviosly have another beer to increase that chance..

http://i982.photobucket.com/albums/ae304/Dukeman2/20170119_194413_zpsyozxhm1e.jpg

Grab that silican ... DONT ... get a gasket sealent that does not set full and block oil ways.. and forget that big gun thing. I found this to be the answer.

http://i982.photobucket.com/albums/ae304/Dukeman2/20170120_160843_zps4ftis4wj.jpg

Find crank case cover and apply.

http://i982.photobucket.com/albums/ae304/Dukeman2/20170119_183752_zpsdzo0gxtm.jpg

apply

http://i982.photobucket.com/albums/ae304/Dukeman2/20170119_195310_zpsptaknuuy.jpg

Torque up as per manual, make sure 3 beers are consumed here to give maximum feel.

http://i982.photobucket.com/albums/ae304/Dukeman2/20170119_203919_zpsg8ntiub0.jpg

and your done.

caseye

22nd February 2017, 15:35

Yeah baby, that is bloody beautiful, nice work there Mr Duke.

Drew

22nd February 2017, 19:12

First thing I don't like in this thread.

I was taught by a very good mechanic that gasket sealant should be see through once applied. It should never be put on thick.

Grumph

23rd February 2017, 06:28

First thing I don't like in this thread.

I was taught by a very good mechanic that gasket sealant should be see through once applied. It should never be put on thick.

Correct - the only exception is vertically split Norton/Triumph/BSA cases which move around when running....

Arronduke

23rd February 2017, 16:19

Thanks guys for the comments.

Well you live and learn, fact is its not that thick. It has flowed out to what you see in the picture.
Hence the syringe for application.

Mind you very little squeezed out and there are no oil ways to foul as its a two stroke.
Put it this way its not a 1mm bead.

The stuff I use does not set as such. All my Dr Google say this is the stuff.

Arronduke

23rd February 2017, 19:43

http://i982.photobucket.com/albums/ae304/Dukeman2/20170120_170301_zpsguaue36s.jpg

This is one of the old rotary disc's, most will know these are to be replaced with a Maranello RG500 Rotary Valve Cover Set.

http://i982.photobucket.com/albums/ae304/Dukeman2/20170120_170335_zpsayqdquzw.jpg

http://i982.photobucket.com/albums/ae304/Dukeman2/20170120_170601_zpsqec8cj8l.jpg

OK now you see the rotary valves come as a kit, if you had just pulled everything apart and threw all the parts in a box.... god forbid I would be F#cked. OK not really the old discs have "L" and "R" on each one. So really its not that hard but taking each disc from a bag marked for each cylinder was a great help. Also the exhaust valves for each cylinder and in the same bag along wit the piston and all associated part. It just makes sense.

http://i982.photobucket.com/albums/ae304/Dukeman2/20170120_173326_zpsozo17iea.jpg

http://i982.photobucket.com/albums/ae304/Dukeman2/20170120_170601_zpsqec8cj8l.jpg

the kit, just need a big hammer to bang those rivets and make sure it all lines up as expected.

http://i982.photobucket.com/albums/ae304/Dukeman2/20170120_171413_zpsuwu5zj2j.jpg

Before the big hammer comes out to play... might be time for a beer. Don't want the shakes now do I!
Hammer and a good sized pin punch and a steel block to make sure everything is flat. Did I say flat.... lets no go there and talk about tits.

http://i982.photobucket.com/albums/ae304/Dukeman2/20170120_173021_zps5ehdnlro.jpg

Inside cover, this needs to be spaced out to provide 0.3mm clearance. The kit comes with heaps of different thickness gaskets. A bit like my kids some are thick and some are thicker, obviously take after there mother.

http://i982.photobucket.com/albums/ae304/Dukeman2/20170120_173045_zpsqxkhfkuj.jpg

Throw in a newly bashed disc, add the cover and measure the gab... we all like a good gap.But unfortunately while we like a big thigh gab we are looking for 0.3mm, still better than the standard thigh rub!!!

Add outer cover and measure... being anal I did multi measuring, just measure the individual parts and calculated the gasket thickness than assembled and measured again. 0.05mm out doing this.

http://i982.photobucket.com/albums/ae304/Dukeman2/20170205_191023_zpshjxmenhn.jpg

anyway back to the discs soon...

just cause I can... fu#k me this looks good.. nice and clean like a good box.

http://i982.photobucket.com/albums/ae304/Dukeman2/20170205_191518_zpsac1rjres.jpg

http://i982.photobucket.com/albums/ae304/Dukeman2/20170205_191547_zpshnnfa9sx.jpg

Dadpole

23rd February 2017, 20:29

Another fix of bike porn. Thanks.

Oh how I wish I had kept my RG400. :facepalm:

sugilite

24th February 2017, 11:15

By your latest post, it looks like you are referring to photos, are you posting photos? If so for some reason I'm not seeing them!

Drew

24th February 2017, 11:18

By your latest post, it looks like you are referring to photos, are you posting photos? If so for some reason I'm not seeing them!

Lots and lots of them.

sugilite

24th February 2017, 11:20

Lots and lots of them.
OK, tried viewing in chrome instead of firefox and i can see the photos, weird shit. Got my fix now though :drool:
Cheers Drew

MENTAL490

31st March 2017, 19:06

I always wanted and rg500, had the kr250, kr1 tzr250 rgv250 and rg400 but never the 5. A few yeas back i was seriously looking at joining 2 cr500 or kx500 liqid cooled engines like the kr n a tandem twin setup, i got a 91 gsxr 250 with no engine for next to nothing but then time got away on me and the esky ate all my cash so i sold the gsxr. If the 500's wernt so far and few between i would still consider doing it, i even bought software to design tuned pipes to keep in nice and quiet. unless i win lotto somehow i don't think its gonna happen so ill just drool over yours

Arronduke

1st November 2017, 19:15

Got over my sulk about Photobucket... time for an update.
How the hell do I post pictures now?

Dadpole

1st November 2017, 19:27

Got over my sulk about Photobucket... time for an update.
How the hell do I post pictures now?

Find a way - Please. I do like a dose of bike porn.

husaberg

1st November 2017, 19:53

Got over my sulk about Photobucket... time for an update.
How the hell do I post pictures now?
post them direct from your PC
Give me a minute
https://www.kiwibiker.co.nz/forums/album.php?albumid=4916&attachmentid=309281
its easlier if your setting are set on
<label for="rb_vbcode2"> Enhanced Interface - Full WYSIWYG Editing</label>

HondaLad

2nd November 2017, 07:27

Got over my sulk about Photobucket... time for an update.
How the hell do I post pictures now?

Excitement levels are high, long been waiting for Arronduke to emerge from the shed and share some more bike porn. Given the time it's taken to navigate around the empty beer bottles and find his way back to this thread one hopes for serious progress.... or at least some entertaining beer addled ramblings.

Most promising post I've seen in ages! :corn::corn:

Arronduke

2nd November 2017, 21:20

Mr Ho#da Lad... sorry cant say that word, tongue got all twisted up. Bit like taking home a hot chick with a raccoon for a pussy who thinks your going to save global worming, when all your thinking is if I don't burn this spread I'm going to die down here... and the only time you want to eat rotten prawn is staving at sea. But being a Ho#da rider what do you do? :wings:

Sorry got carried away... with your last post and intro..

So moving forward the pistons are in and it time to throw on the heads and torque it up. Not so quick... after getting the head studs plated which way do they go?
Common sense said long thread in to the barrels for max grip... after all they are known to strip when torquing up. But NO...why that would be to easy.
Each stud has a round head end and a flat end, long thread has the round head for the dome nuts, where the least thread is used . I will tell you know that this is not in the manual.

Head gaskets are another mind F#ck. They look he same, but have water jacket restrictions which do not make sense for one set of heads. All I can say is it must be to equalise cooling for the inner and outer cylinders where air flow is different. This took some working out, but yes its correct, water flow... and cooling.

a coupe of pictures.

See that f#cken silver thing known as a magneto, its got to come off because i forgot a hose clip mount. Pissed me right off. Obviously not my fault, wife must have asked me to do something trivial like feed them or something. My take on the situation is when they are old enough to ask for food, they can open a cardboard better than I can and find shit they want to eat. Why disturb a man deep in thought about which way round head studs should go. Cos I can say right now 15 beers of thought I could not work it out. The round/ flat ended stud thing must have been Mrs Suzuki's idea of a joke. Small penis / stud with round head and long tread goes on top = Japanese man.

http://u.cubeupload.com/Arronduke/RG1.jpg

http://u.cubeupload.com/Arronduke/RG.jpg

Except that round silver thing, motor ready for install, plan is to do soon know Kat is a runner

F#ck me.. large pictures.. in the post. finger up to Photo bucket

Notice that the studs are around the wrong way in the picture... cant handle those disruptions and not a beer in sight.. I must have given up drinking!

sugilite

3rd November 2017, 07:47

Porn is nothing without photos - so thanks for making the effort - Awesome! :headbang:

Dadpole

3rd November 2017, 12:19

Is there anything more pornerific than a 4 pot 2 stroke?

Arronduke

21st April 2018, 11:30

If this picture works I will add more... RG of loveliness.

http://u.cubeupload.com/Arronduke/20180420152814.jpg

Yes it works so all good, will add some more soon.

Arronduke

21st April 2018, 11:32

And another..

http://u.cubeupload.com/Arronduke/20180420152830.jpg

Arronduke

21st April 2018, 11:56

Have to say posting pictures was getting to hard... until I worked out this site. piss easy.
And large pictures!

Need to plates some screws before the other set of carbs go on. Had to have a speedo cable made to fit GSX600 speedo drive to RG instruments. Company in Wellington did a assume job.
Tight front sprocket add chain.

OH.. not forgetting the wring loom which will go in soon.

http://u.cubeupload.com/Arronduke/20180420152845.jpg

george formby

21st April 2018, 13:00

RG Extensive kleenex.

Dadpole

21st April 2018, 14:45

RG Extensive kleenex.

Says it all really. :shifty:

On a (slightly) related note, a few weeks back I found a RG400 alloy fairing mount in my bits bucket. The one that fits to the lovely raised mount on that slab of alloy frame. That must be all that remains of my brief Summer affair with that scarlet and silver hussy. :weep:

Arronduke

21st April 2018, 15:29

Seems I am on a roll, time for an update.

Cleaning the chambers, OH they look so sexy after all the shit is cleaned off.
Cool thing is the manifolds to make removal easy without undoing the exhaust bolts constantly and rooting them. Planning to use bolts and not studs... coment? with antisize obviously.
Stainless steel bolts? I am thinking not but want to, stainless and aluminium not a good mix. What you say?

http://u.cubeupload.com/Arronduke/20180421121931.jpg

http://u.cubeupload.com/Arronduke/20180421121936.jpg

http://u.cubeupload.com/Arronduke/20180421125654.jpg

Not installed permantly just a test fit, thinking about exhaust wrap where the chambers go past the oil tank etc... loads of heat.. good idea?

http://u.cubeupload.com/Arronduke/20180421150541.jpg

Arronduke

21st April 2018, 15:38

Ah doesn't that look good.

http://u.cubeupload.com/Arronduke/20180421150526.jpg
and even better....

http://u.cubeupload.com/Arronduke/20180421150557.jpg
amazing what happens when the family are away! time to play... now where is that beer!

Dadpole

21st April 2018, 15:42

OOOOHHH. Lurvly stuff.

Isn't there a plate with silver heatproof stuff to shield the oil tank? Probably just my befuddled mind confusing it with some other bike.

Mike.Gayner

21st April 2018, 16:50

This continues to be the best thread on KB.

Arronduke

21st April 2018, 17:31

OOOOHHH. Lurvly stuff.

Isn't there a plate with silver heatproof stuff to shield the oil tank? Probably just my befuddled mind confusing it with some other bike.

correct...
number 6- 44693-20A00-000 HEAT SHIELD,OUTLET 1 0.00 (means not available)
Im sure there was not one when I pulled this fuc#er apart. Mind you that was 10k beers ago. But saying that I have lost FA and nothing leaves my shed unless its empty or trash as you can tell!

Cant seem to find one.. if you have one in the parts box let me know...

http://i.cubeupload.com/SiURTm.jpg

Arronduke

21st April 2018, 17:32

This continues to be the best thread on KB.

Now that just eggs me on with my stupid ways!
Thanks

Arronduke

21st April 2018, 18:09

Now I have had a beer I can rant.... why is the petrol I feed my bikes going to cost so much?
Cows farting.. really. Add no more gas and oil from Taranaki when we have heaps of supply and SHIT LOADS yet to find.
Stuiped fuc$en left, bean eaters, bus users and load mouths. While the rest of us just want cheap fuel to put in our bikes.

Working with the regular price of petrol in USA $0.69 per liter = $0.95 NZ per liter and what do we pay...TAX and shit loads and about to add another 27c (GST ADDED) thanks to the teeth. OMG
All tax in NZ to give $$ to people who do FA.

You might say off topic but NO... I want to afford petrol and use it, not buy it thinking what a treat, lets make it last. Those ass holes dont own an RG5

http://i.cubeupload.com/6K0ODx.jpg

Enough said for 5min..Jacinda Ardern before braces!

http://u.cubeupload.com/Arronduke/JeremyKyleteethMAIN.jpg

OddDuck

21st April 2018, 19:19

[QUOTE=Arronduke;1131095001]Seems I am on a roll, time for an update.

Cleaning the chambers, OH they look so sexy after all the shit is cleaned off.
Cool thing is the manifolds to make removal easy without undoing the exhaust bolts constantly and rooting them. Planning to use bolts and not studs... coment? with antisize obviously.
Stainless steel bolts? I am thinking not but want to, stainless and aluminium not a good mix. What you say?

Not installed permantly just a test fit, thinking about exhaust wrap where the chambers go past the oil tank etc... loads of heat.. good idea?

Stainless fasteners into aluminium: two problems, galvanic corrosion and also the fact that stainless is approx 1/3 the strength of high tensile steel. Galvanic corrosion: you're setting up a shitty battery between aluminium, air, and stainless steel. Everything alloy will go powdery, albeit slowly. This will happen even at room temperature, once the engine is warmed up it'll move faster.

If you're after durability plus the ability to get it all apart again down the road then probably the best way to go is standard header studs (ie high tensile passivated) and the weird copper / bronze alloy head fastener nuts I've seen a few bikes using lately. Alternately if you want cap screw bolts then BZP high tensile will work for a while if you accept that they'll want changing every now and again for the sake of an acceptable light grey finish. The zinc coating is sacrificial, the silvery look of fresh zinc on a BZP will last about a week once they start seeing use. These bolts actually shouldn't get too hot since the header manifold attachments bolt flat to the head and so get the benefit of contact with the bike's water cooling system.

Pipe wrap: fuck no. Please? I've no direct experience with the stuff but everything I've read says it looks awesome after install but everything underneath it rots toot sweet. Something about trapping moisture, including humidity even on a dry day... plus I strongly suspect that there's something galvanic going on at high temperatures as well.

Is some kind of ceramic paint acceptable for the headers? Or is allowing oxidation OK?

Arronduke

21st April 2018, 19:57

Arronduke

22nd April 2018, 19:29

Thought I would try the Rick Lance version 2 air filters... nice bit of kit.

http://u.cubeupload.com/Arronduke/20180421154835.jpg

F me large pictures work here but not on my Kat thread...LOL

http://u.cubeupload.com/Arronduke/20180421154828.jpg

http://u.cubeupload.com/Arronduke/20180421155002.jpg

http://u.cubeupload.com/Arronduke/20180421155016.jpg

These babies should liven up the RG, good mix with the Jim Lomas pipes.
Kit came with two sets of jets 240 and 250, added the 250 to start with and then down to the 240's if needed.
The standard in 120..OMG, but that is what the man says and if you have seen his video / bike they go real well.
Thanks to the teeth this fu#ker will be expensive to run, but you don't own an RG5 if you care about globe warming. This thing is about gulping gas in large quantities and burning oil. Did I mention that smell. Oh the smell and sound of 4 cylinders of 2 smoke power on the pipe.
This has taken a while but the end is in sight and I'm getting excited!

https://www.youtube.com/watch?v=2Dh1EsNTw8E
video Rick lance.. interesting scenery, so different to NZ.

And... why we own an RG5.
https://www.youtube.com/watch?v=lniZg9NoTnw

Arronduke

16th May 2018, 21:25

Cleaned up the wiring loom, 3M tape is the boom and the best I could find on the net for the job. Cleaned all the connectors with CRC electrical contact cleaner, wanted to use brake clean as that is what I had but a few beers on the net, NO... bad for electrical / plastic components. Glad I took the time. Anyway right stuff used and looking real tidy. Time to install. Big step forward. Not much to go now.
Dielectric grease will be use sparingly on the connectors to stop any corrosion moving forward.

http://u.cubeupload.com/Arronduke/20180516204648.jpg

http://u.cubeupload.com/Arronduke/20180516204720.jpg

http://u.cubeupload.com/Arronduke/20180516204731.jpg

http://u.cubeupload.com/Arronduke/20180516204752.jpg

just in case your not totally bored by now.. one more.. not. edit.. did not notice the wife's foot in the picture, ill make sure she is outside next time after cleaning the floor..

OK.. its clean and looking good... also a good reference for other rebuilding a loom, hence the pictures.

Dadpole

16th May 2018, 22:35

did not notice the wife's foot in the picture, ill make sure she is outside next time after cleaning the floor..

If she reads this we may be seeing the RG as part of an estate sale...

Meanwhile - Carry on the good work.

sugilite

17th May 2018, 05:18

Your wife seems to have a very hairy foot - does that help with her buffing the floor after cleaning it?

SVboy

17th May 2018, 10:14

You are a breathing dead man! One day she will read your threads!

Arronduke

17th May 2018, 22:07

Your wife seems to have a very hairy foot - does that help with her buffing the floor after cleaning it?

Hell if you think her foots hairy, wait and see the clean action when she soots around the floor on her ass...
I'm getting the feeling this is not normal?

Arronduke

4th August 2018, 20:03

Gentlemen, or is that to PC... so people, is that inclusive enough?
Just in case we have dress wearing men or jock wearing women you can't be to care full...
A few pictures to update the flock. One might say FA has changed and that might be correct but it is all the small stuff to finish the RG.. Wiring loom install what a fu#king pain in the ass when its done and does not work. Have to say as you get older the horn is not what you remember, it used to be a blast but once I got it working it was more of a limp sound of a horn. Still enough to annoy the wife.
Had to stip back the loom a little to find it was the connector. Now that was a piss off, I looked at the connection and it seemed perfect. Anyway job done and its good.

http://u.cubeupload.com/Arronduke/DSC02797a.jpg

Had to buy a couple of exhaust springs from the Jim Loam site $$$$ had to sell some of the boys PS4 games, ones they have not played for a week. They will never know, and if they do notice then... what the Fu#k you lost another game! not buying you lot any more, you dont take care of them. Useless little AHoles.

http://u.cubeupload.com/Arronduke/DSC02798a.jpg

Arronduke

4th August 2018, 20:54

Trying to install a birds nest of wiring in to a small spot, I had a couple of goes. It only goes one way and without pictures and the stupid manual thats good for FA I was lossing my rag, 17 beers, kick the dog and promise I will not snore AGAIN after telling the wife I dont like spaghetti, I stumbled back to the shed armed with a fresh clean vessel which was telling me to fill it up with the sweet amber nectar from the ever lasting tap in my shed... wife said beer on tap would not end well..., just cant remember when or why see said that. Full of shit as usual.

http://u.cubeupload.com/Arronduke/DSC02801a.jpg

http://u.cubeupload.com/Arronduke/DSC02803a.jpg

All exhaust cleaned and installed. looking assume. installed the power valve controller, the old one was not working so dug in to my spares (bike came with a 400 in bits) and good to go. Took a while to get all the timing right, 1mm slack on each cable. I think I screwed the old one testing it with 12vdc. Not recommend, if it works dont touch it.
Anyway back to the spaghetti just add sauce.

http://u.cubeupload.com/Arronduke/DSC02804a.jpg

Arronduke

4th August 2018, 21:24

Right.. time to try the spaghetti loom again, key here is to feed it all through the head light bracket (in the middle), let it hang like you know you what to. Then fold it up and tie it in place, this time I was quite happy so stand back and see what could possibly go wrong and for once nothing. Front indicator connector are where they should be. All looking good. Pat the dog and tell him he's a good boy. Might even give the wife a pat, I know she likes that!

Notice the fancy - normal looking speedo cable, custom made to suit. Front wheel is GSX600 if you remember and the speedo drive is different. So I sent the old cable and drive unit to a company in Wellington and back came a very impressive speedo cable. Did I add that every cable has been oiled with wire cable lubricant? cut the corner off zip lock bag and cable tie it around the cable and hang it in a vice, squirt oil in to the bag until it drips out the bottom. They will last much longer and not bind. I remember riding home on the RG using the pliers from the under seat tool kit to pull the throttle cable when it snapped, about 60km fu#k did my hand hurt afterwards but I got home, I know one thing for sure if i had rung the wife the answer would have been walk. Why does she not love me.....

Anyway... a tidy nest.

http://u.cubeupload.com/Arronduke/DSC02805a.jpg

http://u.cubeupload.com/Arronduke/DSC02807a.jpg

Dadpole

4th August 2018, 21:38

A set of carbs hanging from the side (where God intended them to be) and a sexy spanny. Perfect bike porn....

Arronduke

4th August 2018, 21:50

Add the instruments.

http://u.cubeupload.com/Arronduke/DSC02810a.jpg

http://u.cubeupload.com/Arronduke/DSC02812a.jpg

Next was the low oil switch, was not reading empty like it should, cant see any thing wrong with it and when I added a little weight / push it works perfectly. My guess is the added weight drag of oil on the float will make it connect as it should. Did not take much pressure to make it work. Cow prodder has a similar affect on house cleaning, you only have to suggest or show the appropriate tool and bingo vacuum is humming. What a nice sound when all you have to do is wave your hand.

Lucky I took off my nail polish for this shot!

http://u.cubeupload.com/Arronduke/DSC02814a.jpg

Arronduke

4th August 2018, 22:09

Thinking of installing this on the RG.. quite like it on the 1230 Kat. Oil temp and volts.
shows 13+v when running and i see the oil temp, going hard its hitting 70+C. Not sure it will tell me the RG is about to lock up but cool anyway.
Sump plug has a oil temp in it...and connected to battery.

Yep 8.3C in my shed at 7pm.

http://u.cubeupload.com/Arronduke/DSC02808a.jpg

and volts on he battery.. sitting.

http://u.cubeupload.com/Arronduke/DSC02809a.jpg

Nice to know when the Kat gets hot, even though its air cooled. 1230 does not like town traffic, who does.

Arronduke

5th August 2018, 15:22

A set of carbs hanging from the side (where God intended them to be) and a sexy spanny. Perfect bike porn....

Thanks very pleased, close to start up..... I will be nervous!

Arronduke

5th August 2018, 18:25

Some will have noticed the carb screw were missing, not any more. Needed a star bit ti remove them and nicely plated screws installed, much better. Did not separate that part of the carb, just used normal screws while these were plated. Nice and look much better!

http://u.cubeupload.com/Arronduke/DSC02815a.jpg

layton

6th August 2018, 21:51

nice work! thats commitment have you been at it a few years?! should be amazing once its finished.

george formby

22nd September 2018, 16:29

Dunno if you have seen this..

RG 500 Isle of Man PoV (https://youtu.be/HWag_JuQDDI)

Dadpole

22nd September 2018, 16:59

Too much talking - not enough engine sound. :no:

Arronduke

25th April 2020, 18:36

Well Gents.. and ladies if there are any....
I'm back.

Long story but I will tell it just for fun.
I read this post and and went OMG... eyes nearly feel out of my head. Wife said fix it and sell it A hole... yea right. Ill do half the order!!!
Non standard RG sells for... really $57k US - $94k kiwi with our F#cked exchange rate at the moment... this has to be a dumb ass with to much $$$

https://www.rzrd500.com/500phpBB3/viewtopic.php?f=19&t=16213

<blockquote class="imgur-embed-pub" lang="en" data-id="lNogZ7t"><a href="https://imgur.com/lNogZ7t">View post on imgur.com</a></blockquote><script async src="//s.imgur.com/min/embed.js" charset="utf-8"></script>

That picture tell a thousand words, the front crank.. with the timing cut out is on the wrong side, the mother f#cker that rebuild my cranks got the inner bearings the wrong way round on the inside of the crank.
So when I went to start it... NO cut out for spark timing. I left it until now... heap of shit.
But the good thing is every thing is balanced so no issue, checked and debated with the knowledgeable people.

<blockquote class="imgur-embed-pub" lang="en" data-id="zcxRhjY"><a href="https://imgur.com/zcxRhjY">View post on imgur.com</a></blockquote><script async src="//s.imgur.com/min/embed.js" charset="utf-8"></script>

<blockquote class="imgur-embed-pub" lang="en" data-id="aYzucDe"><a href="https://imgur.com/aYzucDe">View post on imgur.com</a></blockquote><script async src="//s.imgur.com/min/embed.js" charset="utf-8"></script>

Opened it up and swapped the cranks around and good to go.
Waiting on parts to re assemble.
I walk passed it for quite a while ..(understatement) and gave it the finger.

Long story over, feels good to be back on the job!

My GSXR11 is in bits, fork seals, the RG is in bits.. but the 1230 Kat is a runner for just going to the shop... the long way hee.

husaberg

25th April 2020, 18:59

Shit Aaron its been nearly two years since you posted......
i enjoy the shit you post, it makes my wallet sweat.

SVboy

29th April 2020, 17:52

O.M.G! He is back. My life has meaning again!

Arronduke

16th May 2020, 18:34

O.M.G! He is back. My life has meaning again!
Thanks... LOL

Turned the crank around, we now have a timing cut out for the ignition... what were the chances of fucken that up.
Oh am I still bitter ..... No I think 2 yrs of sulking as allowed me to get over it.

Here is an interesting point... a few people commented on the amount of three Bond I used to join the crankcases first time, I had to agree it did look ugly.
But when I opened the crank cases there was not three bond flowing all over the place, there was a little that had run in the the crank cavity.

So... there had to be a better way. Simple use less...LOL... here is a vid on what it should look like.

https://www.youtube.com/watch?v=nK_HGShNiL8

Also found this vid... great and they way I did it.. only difference was I had about 6 beers which help the finger shake a bit LOL

https://www.youtube.com/watch?v=ZIiQBBaWBBs

I like this method.

https://photos.app.goo.gl/72SaikjZk69BBX126
trying to up load pictures again.... will do soon..

Arronduke

16th May 2020, 18:56

https://i.imgur.com/QrTTHPB.jpg

https://i.imgur.com/6Z5zqaA.jpg

https://i.imgur.com/PAhD1ne.jpg

From memory I applied the gooo to the bottom crank case... read the manual and it said to apply to the top, well F me.
Looks good hey?

husaberg

16th May 2020, 19:07

Looking forward to the day when you let all the thread subscribers stake it for a fang;)

Arronduke

16th May 2020, 19:09

Next on the job list is the tank, there is a little rust from sitting, FA but its there.
I did the heaps of nuts and bolts in the tank with some petrol and put it in my ute for a few weeks to shake it up and then drined.
Did a good job but this stuff is very cool. i will update when I do it... obvious need 10 beers to do it right. Any less and it will be a F up. LOL

https://i.imgur.com/63xQij9.jpg

Dadpole

16th May 2020, 22:13

I should feel dirty after once more looking at all this metal porn.... But I don't. :drool:

Arronduke

8th October 2021, 18:23

I should feel dirty after once more looking at all this metal porn.... But I don't. :drool:

Same... what's changed?

https://u.cubeupload.com/Arronduke/4fIMG5113.jpg

Dadpole

8th October 2021, 19:59

An update - sort of...

Still inspired me to have a trawl back through pages of metallic lewdness.

Arronduke

8th October 2021, 20:25

motor out, Motor in, motor out... motor in

Crank ... fixed

Head gasket leak.... coolant... head off.. head on...

Never buy after market head gaskets.... ever!

Motor back in... holly shit.. funny how engines get heaver...........

Trying to post a vid.............

tomorrow ... video update!

Arronduke

9th October 2021, 07:57

https://u.cubeupload.com/Arronduke/IMG5138.jpg

https://u.cubeupload.com/Arronduke/IMG5134.jpg

https://u.cubeupload.com/Arronduke/IMG5139.jpg

Start up day..........

I have primed the oil pump, added some oil to the fuel.
So it going to smoke a bit.

Front brake needs bleeding, back brake is missing the piston... waiting on parts.
Only been waiting... how long?

It took a bit of effort top start again on the RG... after the disappointment of the crank.
It just sat for a few years@!

I ordered a chain link but the sent me the wrong one, I was planning a short ride fingers crossed.
But no.....

https://youtu.be/536gvsmjfk4

sugilite

9th October 2021, 08:06

Looking Great! Looking forward to the historic start up :yes:

Arronduke

9th October 2021, 20:44

Turn on the fuel, leak...
Turn off the fuel.

Drain bowls ... finish beer go inside... it 6pm.
Well times have changed...
LOL sure!

It goes, needs no choke... and choke floods the carbs on start.

https://youtu.be/rhOnkNX8Bgo

Arronduke

9th October 2021, 20:55

A few beers later, wife is off to cook me some food.... I hope she remembers to keep it warm.

So I had to take the vid.. not that you will notice the difference.
I did noticed the clutch was not working... bugger!

https://youtu.be/vllIUvbxzWY

Dadpole

10th October 2021, 06:20

:drool:................

NAR RG500

11th October 2021, 10:29

SVboy

12th October 2021, 13:34

Well done Aaron. That start should give you the encouragement to finish this beastie.

ojyamaha

17th October 2021, 10:56

Hey there, great project mate . I sent you a message hopefully you see it. Cheers Owen

Sent from my SM-A515F using Tapatalk

Arronduke

19th October 2021, 00:07

Hey there, great project mate . I sent you a message hopefully you see it. Cheers Owen

Sent from my SM-A515F using Tapatalk

Hi Owen - replied cheers

I took the RG500 a ride in the weekend, about 10km up and down the road.
No rear brake - need a new hose.
Front brake - half bleed.

Motor felt nice and crisp, gearbox worked nice with the new 1st gear.. was first that has had the ratio changed from memory.
Clutch - lovely, no griping issue.

Steering head was loose and needs tightening.
All in all - quite a buzz to be riding it for the first time inn ages.

Took the motor to 7,000 RMP - that was enough - fueling felt good from low down right up to 7k.
I say a big thanks to Rick Lance for all his parts that just work so well, RIP Rick.

https://u.cubeupload.com/Arronduke/IMG5212.jpg

Need a new hose, used an old one to cut to the right length and joined it with a insert and glue, easy to be copied.

https://u.cubeupload.com/Arronduke/IMG5215.jpg