Hey all Picked up a "back of the shed" RGV250 VJ21 yesterday, needs a little love for sure, it'll be a slow burner project for me. Got this for a fairly decent price, has clean ADR compliant frame so can be road registered if I get headlights etc. It was last run 2 years ago apparently Main things I want to tackle first: - inspect compression etc - inspect electrical system - inspect/clean up power valves - inspect/clean fuel tank - rebuild and sync carbies - fit 17 inch rear wheel for better tyre options (from VJ22?) Any recommendations are welcome! I've always wanted a 250cc 2-stroke, ever since owning the Aprilia RS125 as my first bike; hopefully it's not a case of "don't meet your idols"...
Know that feeling! Photos can be deceiving but it looks in great shape and would be a ripper around the track WORKSHOP MANUAL - Suzuki RGV250 Service Manual | 2FIFTYCC.COM - Home of the Quarter Litre
Found this site while googling .... know nothing about it but appears to be Australian ..... RGV250 VJ21
Found a few more resources for the RGV .... the "hop up kit manual" looks like a good read .... RGV250 | 2FIFTYCC.COM - Home of the Quarter Litre
Ok so, cleaned out the carbs, checked the spark, put some oil down the plug holes Took a handful of kicks but she started! Got some air leaks to chase I think, shall replace all hoses and cables. Is there a definitive way to measure the carbs? I measured the ID on the engine side (outlet of the carb) and seemed to measure 34mm Which would say they are the TM34s from a VJ22? Just need to ensure I get the correct kit and jetting...
Looking at these rebuild kits from AliExpress, they come with a Needle Jet (discontinued) and four different Needles (also discontinued) Assuming they have different needles to accommodate different tuning etc, but how would you know which one to use? https://a.aliexpress.com/_mMQdegd
Well posty dropped off all the goods today - complete sets of new cables from Venhill UK (throttle, carbs, choke, actuators, speedo, clutch) - a box of carb spares from Impex Japan I have a 17 inch rear wheel ready to swap on too Only thing I overlooked was a rear master rebuild kit
Well a productive few days... Firstly, rebuilt the carburettors, overall this went well, found a couple odd things, 140 main jets (stock is 270), and air screws were wound fully closed and missing their springs. Floats seem to be deteriorating so I'll be on the lookout to replace them somehow Next I replaced all the cables, throttle, choke, power valves, clutch, speedo (and installed a speedo). Again a bit fiddly but all in all pretty simple Inspection of the power valve pulleys shows they need replacing too (becoming oval), looks like another order to Impex...
Following the carb rebuild, she started up pretty much first kick (actually hand started lol). Today did some other checks, compression seems to read consistent on both cylinders, only a cheap chinese gauge though so can't comment on the accuracy of the readings Next investigation into the power valves as I noticed a noise from the RH cylinder Long story short, seems the valves have been lightly kissed by the rings, some roughness to the end of the valves seems to be the tell tale indicator Having said that, the rough piece I believe is the guide piece and is in a fixed position, so I can't imagine that encroaching on the piston? Noted the retaining holes etc have become oval too Looking at the pistons through the inspection port, I can't see any noticeable damage so maybe I've caught it before it progresses too far? Anyway, I have a few options: - remove the valves and blank em off - short term, grind the ends off the valves to give more clearance temporarily - pull off the cylinders and inspect for any damage, if we're good then I'll probably just swap out the rings and new valves, otherwise full top end rebuild As it stands she's just going to be a track bike for now
Working on the prettier side of things while waiting on parts, rebuild and painting the calipers and fairings (just a rattle can job) Anyway this sticker on the tank is a bit crusty, a google image search found a replacement on amazon japan haha, no shipping to Aus though.
Been a busy few weekends on the RGV and the rattle cans Painted the rearsets, side stand, clip ons, clutch lever and front screen stay, as they were flaking Painted the calipers a nice blue, rebuilding these over this weekend just picked up the last two seals today! Painted the exhausts with some high-heat black Spent some hours cleaning the frame etc as much as I could haha, aluminium has come up quite nice although I can't seem to get some stains out of the swingarm Hoping to start tackling the fairings too if i get time But next on the list is inspecting the cylinder bores and power valve clearances, fingers crossed!!
Ok so pulled off the cylinder heads to inspect the bores and power valve clearances Bores look ok, LHS seems like it's going to be due for a hone soon Powervalve clearance is ok, they are also due for replacement though, while I was in there I replaced the PV seals too Rebuilt the calipers, they have come up pretty nice if I may say so myself! And for the first time ever I actually had success with a screw extractor...
Well got the RGV to Queensland Raceway for it's inaugural run, did one session but then swapped back to the ZXR. Had some issues with the RGV bogging at around 10krpm, especially on the main straight and a few times on the smaller straights Possible causes? - inline fuel filter I installed one although it isn't meant to have one stock, it's a mesh type and in hindsight it has a bigger mesh than the petcock so it's probably pointless. I also notice it only ever seems to be half-full, it's also installed horizontal which probably doesn't help - blocked jet I de-rusted the tank and cleaned it as best I could, but maybe something has slipped through onto one of the jets - incorrect jetting I'd expect it to happen consistently if it was incorrect jetting? Also, even after hours of bleeding, the front brakes are spongy as. The master cylinder performed well when connected to a dead-headed line, so I don't think its that (also it's a brembo 16mm radial), possibly an issue with the caliper rebuild?
