Here's another RD500/3MA project nearing completion.

Message

jetskijerry · #1 Post by **jetskijerry** » Wed Oct 31, 2012 8:10 pm

I have been building a YZR500 replica for the last year or so. Pics of build on Flickr.................

http://www.flickr.com/photos/woods964/

It's ready for first test, probably at Brands Hatch Circuit, although the 'gritters' have been out already so I'll have to pick the right day!! All being well, it's then the final strip and rebuild with paint and polish! I think it's going to be the Sonauto Mobil1 colour scheme from 1991 although research has shown some really obscure colour schemes....especially some of the Japanese wildcards! Loads of pics of these to add to the photostream when I get a moment![/url]

Ronnie · #2 Post by **Ronnie** » Thu Nov 01, 2012 5:35 am

WOW! That looks an excellent job. Some first class engineering. I like the air filters. Can't believe you kept this quiet for so long!

rich bullock · #3 Post by **rich bullock** » Thu Nov 01, 2012 5:53 am

Well done that is one very impressive looking piece of kit. Good progress photographs too. Whose bodywork and pipes are you using. Like the front headlight set up. Whatever paint scheme you use will only make it look even better.

Andrew · #4 Post by **Andrew** » Thu Nov 01, 2012 10:16 am

Nice one!
and welcome to the group

jetskijerry · #5 Post by **jetskijerry** » Thu Nov 01, 2012 3:37 pm

Thanks guys. I was going to post something months ago....but I sorta got a bit involved with the bike!!....and work got in the way too!!
Bodywork is from genuine 1990 YZR500 moulds....see Harris.....exhausts and radiator, custom made by Mark Dent...lovely work. Headlight is a projector with dip and main in the one unit....took a while to find!!
As you can see, it's obviously a 3MA frame and RD500 lump. Front end is 1999 YZF-R1 with internals reworked and travel reduced. Rear end is 2006 YZF-R6.....pivot bearing area narrowed to fit. It can be.....just!! Almost all the work done 'in the shed' apart from the ally welding....I must get a TIG. I hate not being able to do it all myself.....ie waiting for others!

RGVSTEVE · #6 Post by **RGVSTEVE** » Thu Nov 01, 2012 4:39 pm

I see your using one of Nigel Kimbers frames.

jetskijerry · #7 Post by **jetskijerry** » Thu Nov 01, 2012 4:41 pm

Yes NK did the engine mounts. Next one will use different frame.....I think there's going to be too much flex in the kickstart area. I designed and fabricated the rear suspension mounts. Track test will show if they are OK!!!

jetskijerry · #8 Post by **jetskijerry** » Thu Nov 01, 2012 4:43 pm

Photos of 1991 YZR's with various sponsorships as well as original YZR details now on Flickr Photostream.

Dubsey · #9 Post by **Dubsey** » Thu Nov 01, 2012 4:55 pm

Hi Gerry,
wow that is so so much better than you desrcibed
Excellent build
your pics bring back some painful memories of my build
lost your card you gave me at brands

did you find the thread re. the carbs ?
Let me know when you are running at brands, i'll try to get along
cheers Mark

jetskijerry · #10 Post by **jetskijerry** » Thu Nov 01, 2012 6:09 pm

Thanks Mark. From what I was able to discover through various sources, the original carbs were designed to have the powerjets built in to the castings 'just in case' they were needed. They apparently weren't, but the castings weren't changed....the 'breakthrough points' were just not drilled. I did a few sessions on the dyno and worked out that the airflow through the standard carbs, once porting done and pipes fitted, with the very free-flowing air filters that I made, was too free-flowing. Some restriction on the air intake, much like the original 'elephant ears' and airbox gave, in combination with the adjustable powerjets, worked wonders. I'm getting 98bhp at 11,250rpm (at the back wheel) on a dyno that by all accounts is a little pessimistic if anything! I'm happy with that.....for the moment! I'd really like to move things around. Shift the powervalve mechanism to the R/H side of the cylinders and put the carbs in the 'V' or even go the fuel injection route. Has anyone got that right yet? Jerry

alexander · #11 Post by **alexander** » Sat Nov 03, 2012 5:40 pm

I tried again today, linky no worky.

Ronnie · #12 Post by **Ronnie** » Sat Nov 03, 2012 6:49 pm

Link wasn't quite right. Try it this way and go through the pages.

http://www.flickr.com/photos/woods964/

jetskijerry · #13 Post by **jetskijerry** » Sat Nov 03, 2012 7:35 pm

Thanks Ronnie. Not quite sure what happened to the link. Probably when I added the new photos!

Ronnie · #14 Post by **Ronnie** » Sun Nov 04, 2012 5:57 am

It wasn't quite right with your original post but I worked it out!

RC45 · #15 Post by **RC45** » Sun Nov 04, 2012 10:15 pm

Nicely done.

Another slips out from the shadows

500 Two-Stroke Tech

Here's another RD500/3MA project nearing completion.

Here's another RD500/3MA project nearing completion.

yzr rep