Any advice for an unknown qty 2 smoker?!

[Hahn]

Just got a rgv250L (seems to have 89,90,parts with 91 fairings), picked it up cheap because of the high ks (51k) and rebuilding it.

So far i have:

Cleaned the hell out of it!
then,

Started with the brake lines, bleed them and still spongy as hell, so binned them for braided lines. new rear pads, had to split the caliper to get them in... doesnt look good, hopefully pistons wont leak! also on brakes, should i use dot 4 or 5 fluid?

Ordered new Power valve actuator cables, bottom valve was jamed open. no wonder it had nothin under 8000rpm.

Pulled the powervalves and after getting them out with an impact driver, replacing philips screws with internal hex, who thought philips heads in a hot end was a good idea? anyway PV look good, after carbon removal, no cracking or fracturing, a little scoring on rear cylinder pv faces. Apparently the pin can fail and blow the engine?
Nil marks on the rear piston i can see through the exhaust and PV ports a little wear on front piston from exhaust port divider.

Attempted to remove carbon from expansion chamber and exhaust... no luck yet... will try and get hold of an oxy acetylene torch, that should fix it!

Thinking about doing a top end rebuild.... cost and where do i get a kit?
And exhaust, expansion chambers for more power. any susgestions?

Any help/advice will be appreciated.

[vagrant]

Hi Hahn,
Welcome to KB.

Have a look here for allsorts of good gen on your RGV.
http://www.rgv250.co.uk/technical.htm

They used to have the workshop manuals there as well, but I guess the copyright Nazis gave them the hard word.

As for your brake fluid, dot 4 will do fine. It's boiling point is lower, but it does not absorb water as readily, so will last longer. Dot 5 is only needed if your riding and braking 10/10ths everywhere.

Good luck with the rest of your tidy up.

[Hoon]

Yep dot4 or 5 brake fluid. You aren't suppose to mix them so whatever you choose flush the system and use that from now on.

I rebuilt the top end of my RGV. Buy online is a lot cheaper. I think my Wiseco race pistons and rings only cost about NZ$200 from some US site so shop around.

I might have a service manual file saved somewhere so PM me if you don't have one.

[breakaway]

I use dot 5.1 (Motul). Flush the system out with meths first though.

[Squiggles]

I use dot 5.1 (Motul). Flush the system out with meths first though.

Note that he says Dot 5.1, not 5, 5 is silicon based and is not what you want to use.

[breakaway]

Heh nice ninja edit thar

[Squiggles]

Heh nice ninja edit thar

yer, remembered the diff between 5 and 5.1

[Hahn]

Cheers guys. should have the bike rideable by the end of next week!
Anyone know of anyone who does expansion chambers/exhausts?

[FROSTY:Me]

2 points dude-1)re parts--give Billy on the site a yeodle--hes still got shit loads of Rgv stuff.
2)check your barrels thoroughly-- the 89 had a rep for the chrome lifting.