RC45's RG500Γ XR45 Project - Full XR45 Bodywork located!

[ns86]

I have 2 fairly beastly RGV500's myself and you're right, more than several pocket's full of cash went into them. One running Jolly's one running JL's. The numbers that matter in this comparison being the difference between the 400/500. Just trying to figure out what route to go myself. When they say 59hp @ crank for the 400 what would you expect the cheapest conversion [bore & pistons]to 460cc to cost and output? I assume some exhaust restriction on the 400 to account for the huge difference in spec HP , 59/95. So apples to apples, RG400/460 rejetted with RG500 stock pipes compared to stock RG500? Mark350lc's resleeved 500/5 port puts out 100hp with significant porting/pipes and your rebarreled 550/7 port puts out 127hp with porting/pipes. Seems your's is higher output/cc. 50cc=27hp!

[begbie]

The 400's were only restricted by the 135 main jets (500's ran 120's) the exhaust dimensions are the same apart from the stingers which are 2mm smaller in dia due to the smaller bore size of cylinders.
the 400's power (once 120 mains are installed) is pretty much in line with the 500 cc going by my own dyno findings cc, 500cc divided by 5 = 15hp per 100cc, 15hp times 4 = 60.
I have no personal expirance with 460 over bores but with the right pipes, prog ign with advancer and optimsing CV / squish I would be aiming for 80/85 RWH. It would be an intresting project.

[RC45]

Well it's on now.

RG Frame, RG swinger, 86 GSXR front end, RG500Γ XR35 dash bracket, RG500Γ Gamma XR45 tail piece, classic RGΓ XR style upper fairing, Sugaya pipes, RGΓ temp gauge inbound.

I am going for classic look here. Not sure about engine yet - maybe tuned big bore 400, seems the more economical way to go.

I am on the hunt for 2 piston race brake calipers. When folks upgraded their race bikes to four piston calipers int he early 80's, did they throw the old 2 piston units away? Struggling to find them anywhere. I think I will even run the brakes ahead of the forks.

On the hunt for someone to make the bespoke RGΓ embossed alloy tank

[ns86]

This is an informative link about the 400 engine. Just learning/deciding myself. Bored 54mm 400 uses 1985 CR125 pistons, Pro-X. Pistons require machining for small end clearances meaning wrist pin diameter I assume? Also requires decking of cylinder and re-profiling of head. Rear transfer ports need correcting and rotary valves need to close later. Durations are in the thread etc.
http://www.rgv250.co.uk/forums/index.ph ... -chambers/" onclick="window.open(this.href);return false;

[RC45]

I am trying not to blow my entire modded Gamma Square Four engine budget on this....

Brand new never used RGB500 tank.

[RC45]

This is an informative link about the 400 engine. Just learning/deciding myself. Bored 54mm 400 uses 1985 CR125 pistons, Pro-X. Pistons require machining for small end clearances meaning wrist pin diameter I assume? Also requires decking of cylinder and re-profiling of head. Rear transfer ports need correcting and rotary valves need to close later. Durations are in the thread etc.
http://www.rgv250.co.uk/forums/index.ph ... -chambers/" onclick="window.open(this.href);return false;

From what I have been told, the re-sleeved 400 barrels are not ideal - they are significantly heavier, the new bigger sleeve shrouds what little port volume is left and I believe I was told the power valves tend to bind due to liner expansion when the motor gets hot and is run really hard on track.

Bored stock 400cc barrels or retrofitting 500 barrels to the 400 cases appear to be the most direct and most cost effective ways to get to where I am trying to go. With the bored 400 option being the slower lower power but cheaper alternative.

I think I am going to focus on the roller and get it all the way to where I need it and then just gamble on a suitable donor engine appearing on my doorstep one day

[begbie]

Or if budget allows I know the item has ended but they are still available new .

http://www.ebay.co.uk/itm/Brand-New-Cyl ... 1462856559" onclick="window.open(this.href);return false;

[RC45]

I guess I am going over bored 400cc for the first version of the engine. RG400 cases, cylinders, cranks and heads in-bound. This lot was less than the cost of the 500 cylinders - including shipping.

[begbie]

I think thats a wise choice, and the way I would if building another.
Look forward to following your progress.

[ns86]

A 50/50 chance I will be going that route myself. No re-sleeving for me. Even if I get barrels at cost through my friends Suzuki dealership they will be a minimum $1500 for the set. That will go a long way toward building a big bore 400. Having 2 500's already there is a certain allure to it as well. Still undecided though since $2000 may well get me to a full stock 500 engine if I get all my parts at cost and machine my own heads and upper cases. In my case my bike is a registered RG500 roller that was a donor for one of my hybrids and could be a very nice stock bike again. For me it would be wise to make it a stock RG500 since I don't have one to complete my stock RG/RZV/NS collection. I look forward to your build as usual!

[RC45]

I like the look of this bike. Now to find a set of RG500 XR45 brake rotors.

[andy]

In the event any of you are looking for a 500 gamma motor/carbs/electrics I have one nearing completion.
Best to drop me a note thru the site, http://www.alienracing.net" onclick="window.open(this.href);return false;

[RC45]

Lucky Strike, Marlboro, Rothmans etc... sponsor decals for lots of brands of cigarettes, but finding HB decals is proving a little difficult.

Any ideas?

[rd84]

Hi,

It might be possible to use the decals from a model motorcycle to use as masters for full size ones such as these........

http://www.spotmodel.com/product_info.p ... s_id=13907

Probably do an high resolution scan of them and then correct, enhance or change in Photoshop as required.

Cheers
Paul

[RC45]

I have no problem with scanning and cutting vinyl on the cutter. Stripes, number boards and major graphics elements etc. - but for multi-colour sponsor logos and the like I prefer to use actual screen printed stuff. Just looks the part.

I guess its off to the local printer then.

*edit*

I just sent an email off the British American Tobacco - I think they own the brand, so hopefully they respond that they have stickers galore for sale