95 RGV 250 Rebuild

Not sure about that.
I spoke to Loz & he wasn't impressed, got some advice on jetting which matched what we were thinking.
I think we'll get it going first, this weekend, & see.
The dyno scares me a bit not knowing where the tune is, don't want to nip it up after all this expense.
I'd like to run oxygen sensors on it like we do on the 2 stroke kart engines, they tell us where we are at for mixture ie lean or rich but they are $280 ea & we'll need 2. Just sent the tank in for some dent repairs & that'll be another $300.
The zeel tronics are on hold for now till we see how it runs with the std box. I suppose it'll get the better of me eventually & we'll buy it but house renovations are in progress, happy wife = happy life.
Some of the last of the parts turned up today, levers, new throttle grip, used tank cap & matching ignition cause the old ones had a screwdriver for a key.
The guy at F1 Moto that did the barrels & valves was Rob Benge but there no contact details to get in touch any more. He has an RGV with the same mods & he's been through what we are about to go through.

 

Ok thanks for the help.
The leaner carb makes sense

Yeah your right there, only need one I didn't think of it that way, I would leave it fixed to the bike. We run a water temp gauge on the NSR, hangover from the karting & a paranoid pilot but it doesn't hurt to keep an eye on things especially in traffic in summer.
I'd be keen for a dyno run to get her tuned & to see what she's putting out, probably more like 50hp at the wheel in reality.
I'll get in touch with Loz about it, he got a bit excited about the dyno tune, but not for a while, I'll get her registered so we can run it in a bit before screaming it's head off on a dyno. Weve had plenty of experience seizing engines in kart racing. The tolerances we ran were if we didn't run 3 sessions running in a fresh motor it always seized, sometimes we just didn't get the track time & tried to race them with only 2 sessions & they seized. Not going to risk it with this little baby.
I'll post a video of the first run if we do it this weekend.
Dad got all the parts today & yesterday, he's actually fitted most of it all today.
All the timing is set for the valves & oil injection / flow, carbies are all set. He will fine tune all the solenoid actuated gear tomorrow as he's only just got the new ignition switch today with the new throttle tube.
One thing he commented on is the throttle cable is very heavy when all connected but not to the tube, he connected an old GSXR750 tube today & said it felt good but strange it's heavy pulling by hand, everything is free & light elsewhere ??

 

We run the digital water temp guage on another 2 stroker without a guage, he likes to keep an eye on the numbers, you get a feel for when they start to get out of control & in fact that one runs too cold & he often tapes up a part of the radiator.
The RGV isn't a race bike, just a pleasure ride, a bit of self satisfaction. We are mechanically grounded rather than cosmetically. I ran around on my ZXR for 18 months half painted & half primed but different story under the covers.
The RGV's oil injection system is simple & foolproof, it's all bled & flow rate is set.
No coolant in her yet but I'll make sure she's bled thoroughly.
She'll be treated like a baby, won't see 12k rpm very often on the roads, not a big believer in revving the **** out of engines all the time, different thing on the track though where rebuilds are regular.
This bike's a keeper, or at least till the economy catches up to what it owes us ! We set out to buy these basket cases & do them up, enjoy them for a while & sell them on but the garage is overflowing into another now & I've had to build another one for future growth.

 

Well she's ready to start, booked in for 3pm.
The key was turned today & all the right noises were made & everything cycled perfectly.
Got the oils & new spark plugs ready for tomorrow.
3 of us are going up to the Bay at 2:30 so I'll have footage tomorrow night when we return.
Not sure how to upload such a big file though ? I see some are via youtube but that's out of my range too, I could work it out but I'm not sure I've got the time.
Some more pics with all the trimmings except for the fairings.
All that's left to buy are the rear blinkers & mirrors with integrated blinkers. I want small neat LED rears to hang on the tail tidy but they're hard to find either cheap crap or too expensive jobs

 

Stay out from under it ! Remember what happened last time. She might cook you a nice home made dinner ? Nothing better than that !
Driving up in her/our car, got Ross, Sam & Will. Had to empty the ute into the tipper this morning so she could leave me the car & she took the ute, now I'm all itchy for the day, old glass fibre insulated suspended ceiling tiles , she's happy. you know how it goes !
I've got to get a couple of metres of 8mm fuel line, all the stuff that size has been big heavy stuff & I want nice neat thin wall line, the kart shop's gear is all 6mm.
It'll be the test to see if she goes first kick, the way Dad puts engines back together I'm betting it will.
She's better than new, gunna really enjoy having her around.
Next project is the big old XS1100, started sandblasting engine parts already, I should be painting the RGV fairings though.

 

I think I'm the majority shareholder, hard to tell with all the transferring of tax return funds & other cash deals between him & his mother. David Jones probably holds the balance of shares by now cause I haven't seen any of it !
The bike's not here, it's up at Dad's. I'll get it back when the fairings are done, no room here at the moment.

What are you doing up at this ungodly time of the day anyway ?

 

Well, no go.
All called off because there's a hole in the inlet port into the water jacket letting water into the cylinder.
Barrel off today for a look to see what's what.
I'm sure it can be repaired but WTF, can't say how it happened yet, maybe a machining issue or maybe a crack, but it wasn't there before !

 

No it's all good news. He could hear air escaping like it was from the inlet port but it was from the base.
The base gasket caught on the cylinder as it went into the crankcase & got dragged in so the base was un sealed & has allowed the water to fill the crankcase.
Engine out again & a clean up.
We'll be replacing the other gasket as well, cant stand the thought of not knowing if the other one is gone too.
Thats what you can expect from after market parts.
The new ones will be OEM if theyre available.
Bit of a relief from what we originally thought.

 

New genuine gaskets on the way from Melbourne $30 so not bad.
The other gasket was ok. The skirts that protude into the crankcase are as cast & not accurate sizes so not really the gaskets fault. We'll see how the genuine ones fit.
That won't happen again !
Maybe a mid week start up when they arrive.
We'll have our new fuel line by then too.