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 Post subject: Re: V4 RGV500
PostPosted: Sun Apr 05, 2020 4:14 pm 
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Yeah Man, the Interstate
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Joined: Wed Jan 01, 2014 2:04 pm
Posts: 539
Country: UK
Suzuki 2-Strokes: GT750 hybrids (x2) VJ23A RGV500 TS185 R250
a productive afternoon - V4 motor installed in the SRAD frame, rear top and bottom mounts fabbed and fitted.

The fronts require welding up, so they are absent from these photo's..........

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Garry


I'm addicted to brake fluid, but I can stop anytime.


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 Post subject: Re: V4 RGV500
PostPosted: Tue Apr 07, 2020 7:53 am 
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Yeah Man, the Interstate
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Joined: Wed Jan 01, 2014 2:04 pm
Posts: 539
Country: UK
Suzuki 2-Strokes: GT750 hybrids (x2) VJ23A RGV500 TS185 R250
not a great deal of progress today - spent most of the day washing / polishing / detailing the MX5 - its been a bit neglected for the past 6 months.

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Then a spare hour in the garage, during which I drilled 8 x 9mm holes into the beam frame, into which I inserted 8 x 6mm Rivnuts, into which I screwed the mounting bolts for the 4 ignition coils.

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Garry


I'm addicted to brake fluid, but I can stop anytime.


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 Post subject: Re: V4 RGV500
PostPosted: Tue Apr 07, 2020 2:51 pm 
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Yeah Man, the Interstate
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Joined: Wed Jan 01, 2014 2:04 pm
Posts: 539
Country: UK
Suzuki 2-Strokes: GT750 hybrids (x2) VJ23A RGV500 TS185 R250
just enough spare time today to refit the carbs...............

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and to re-work and mount the twin-pull choke levers.........

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Garry


I'm addicted to brake fluid, but I can stop anytime.


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 Post subject: Re: V4 RGV500
PostPosted: Mon Apr 13, 2020 6:45 am 
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Yeah Man, the Interstate
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Joined: Wed Jan 01, 2014 2:04 pm
Posts: 539
Country: UK
Suzuki 2-Strokes: GT750 hybrids (x2) VJ23A RGV500 TS185 R250
It's a lot easier without the road gear..............

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bike all wired-up now - awaiting delivery of the battery then I can have a play at programming the Zeeltronic. Gulp.........

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Garry


I'm addicted to brake fluid, but I can stop anytime.


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 Post subject: Re: V4 RGV500
PostPosted: Fri Apr 17, 2020 9:33 am 
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Yeah Man, the Interstate
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Joined: Wed Jan 01, 2014 2:04 pm
Posts: 539
Country: UK
Suzuki 2-Strokes: GT750 hybrids (x2) VJ23A RGV500 TS185 R250
some good news, and some bad news.......

Good news is that the new RGV250 battery and modified battery box I fitted to the Steam Triple is now unsuitable for use.

So I drilled 3 holes:- 2 in the back of the SRAD's head stock and 1 in the cross piece and inserted 3 Rivnuts......

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the top 2 holes are for mounting the battery box, the lower one is to secure the "Z" bracket, when it arrives.

I then removed the battery and battery box from the Steam Trip and fitted them to the V4, like so..........

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The bad news?

I now have to buy a new 10amp/hr battery for the Steam Trip............ :(

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Garry


I'm addicted to brake fluid, but I can stop anytime.


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 Post subject: Re: V4 RGV500
PostPosted: Fri Apr 17, 2020 12:08 pm 
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Yeah Man, the Interstate
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Joined: Wed Jan 01, 2014 2:04 pm
Posts: 539
Country: UK
Suzuki 2-Strokes: GT750 hybrids (x2) VJ23A RGV500 TS185 R250
remainder of the electrics now have a home.

fuse box and Zeeltronic control unit on upper rear engine mounting casting.........

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(scabby) rectifier on rear of fuel tank bracket.........

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and water pump controller on rear sub frame.........

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Garry


I'm addicted to brake fluid, but I can stop anytime.


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 Post subject: Re: V4 RGV500
PostPosted: Fri Apr 17, 2020 12:11 pm 
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Yeah Man, the Interstate
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Joined: Wed Jan 01, 2014 2:04 pm
Posts: 539
Country: UK
Suzuki 2-Strokes: GT750 hybrids (x2) VJ23A RGV500 TS185 R250
Unsure whether to go with the standard SRAD hump seat unit or this (broken) VJ23 race tail...........

Image

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Garry


I'm addicted to brake fluid, but I can stop anytime.


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 Post subject: Re: V4 RGV500
PostPosted: Sat Apr 18, 2020 8:08 am 
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Yeah Man, the Interstate
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Joined: Wed Jan 01, 2014 2:04 pm
Posts: 539
Country: UK
Suzuki 2-Strokes: GT750 hybrids (x2) VJ23A RGV500 TS185 R250
So, today I stripped the Steam Triple of all unnecessary parts so it's ready to go for it's 3-1 exhaust making and fitting next week.

Can't do anything on the V4 until postie / couriers deliver a stack of parts I've ordered.

So I set to tidying the garage. Started with the parts shelf above my workbench - and the 4th unmarked box I opened contained a pleasant surprise!

After studying how to modify it to fit the SRAD, I fired up the lathe and relieved the mounting nut of some internal threads and surplus metal........

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so that it is a snug fit on the SRAD top yoke nut..........

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then I carefully drilled 4 x 5mm holes into the mounting nut.........

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which enable the mounting bracket to lock to the mounting nut........

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which, in turn, allows the mounting bracket and mounting nut assembly to lock onto the SRAD top yoke nut..........

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so I can fit the new Scott rotary steering damper I unearthed earlier.........

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I'll modify the mounting post tomorrow.

Note:- the 4 x 5mm cap head bolts will be replaced by some grub screws, which I've just ordered off ebay

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Garry


I'm addicted to brake fluid, but I can stop anytime.


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 Post subject: Re: V4 RGV500
PostPosted: Sat May 02, 2020 3:00 am 
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Yeah Man, the Interstate
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Joined: Wed Jan 01, 2014 2:04 pm
Posts: 539
Country: UK
Suzuki 2-Strokes: GT750 hybrids (x2) VJ23A RGV500 TS185 R250
frame notched - on the inside only - to facilitate #1 carb fitting and removal........

Image

_________________
Garry


I'm addicted to brake fluid, but I can stop anytime.


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 Post subject: Re: V4 RGV500
PostPosted: Mon May 04, 2020 2:42 am 
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Yeah Man, the Interstate
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Joined: Wed Jan 01, 2014 2:04 pm
Posts: 539
Country: UK
Suzuki 2-Strokes: GT750 hybrids (x2) VJ23A RGV500 TS185 R250
made a start on the r/h airbox - because of space limitations there will be 2 separate boxes joining 1 bigger box that has the air feeds.

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as I can't weld (should have learned a long time ago) I have to rely on sticking bits together with chemical metal and waiting an hour or so for it to harden.

the finished item will look much better than this.

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Garry


I'm addicted to brake fluid, but I can stop anytime.


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 Post subject: Re: V4 RGV500
PostPosted: Sat May 09, 2020 10:57 am 
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Yeah Man, the Interstate
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Joined: Wed Jan 01, 2014 2:04 pm
Posts: 539
Country: UK
Suzuki 2-Strokes: GT750 hybrids (x2) VJ23A RGV500 TS185 R250
well, the part-finished item turned out to be a pile of crap - don't know what I was thinking when I started it.

Anyway, it's been consigned to the scrap bin (having first spent £8 to have it welded) now and after a serious rethink, I've started on box #2.

I bought a good, used SRAD air box for £13 off everyone's favourite auction site and made a tunnel for #3 carb......

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then made a floor and side for #4 carb before running out of 2mm aluminium sheet......

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just had enough scrap material to make the floors for #1 & #2 carbs - waiting for a delivery of 2mm sheet now.......

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_________________
Garry


I'm addicted to brake fluid, but I can stop anytime.


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 Post subject: Re: V4 RGV500
PostPosted: Mon Jun 01, 2020 5:27 am 
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Yeah Man, the Interstate
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Joined: Wed Jan 01, 2014 2:04 pm
Posts: 539
Country: UK
Suzuki 2-Strokes: GT750 hybrids (x2) VJ23A RGV500 TS185 R250
carb #'s 3 & 4 air feed tunnels welded.............

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_________________
Garry


I'm addicted to brake fluid, but I can stop anytime.


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 Post subject: Re: V4 RGV500
PostPosted: Mon Jun 01, 2020 11:05 am 
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Yeah Man, the Interstate
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Joined: Wed Jan 01, 2014 2:04 pm
Posts: 539
Country: UK
Suzuki 2-Strokes: GT750 hybrids (x2) VJ23A RGV500 TS185 R250
Early production SRAD 600's share the same instrument housing as the VJ23, albeit with different speed and rev markings.

I have 2 sets of VJ23 T instruments and these would bolt straight on to the SRAD's mounting bracket, then just a case of plug n play, but I found a set of Aprilia RS250 instruments in a cupboard in the garage and decided to fit those instead. Benefit of these instruments is that I can mount the rev counter centrally, like a race bike, with the small LCD panel for speed / temp / lap timer off to the side.

Unfortunately, Aprilia didn't copy Suzuki's mounting template and none of the mounting studs aligned with the holes in the SRAD bracket.

So, I made a template to fit the SRAD bracket and the Aprilia instruments...........

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mounted the template on the SRAD bracket.............

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and mounted the Aprilia instruments to the template............

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just need to lose the top right side mounting, or find a set of idiot lights to mount there as the instruments only have a low oil warning light in built.

_________________
Garry


I'm addicted to brake fluid, but I can stop anytime.


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 Post subject: Re: V4 RGV500
PostPosted: Tue Jun 02, 2020 11:59 am 
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Expert racer

Joined: Wed Jul 10, 2013 12:04 pm
Posts: 1075
Country: England, UK
Suzuki 2-Strokes: FZ50, GP100, RG125 Gamma, GT380, Bandit 1200S
You are very brave...and patient. That's a lot of fiddly engineering you're doing. It looking great though. Can't wait for the next instalment!


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