V4 RGV500

[garry55]

collected my parcel of goodies, ordered from RGV250 specialist Sean at TTW, which arrived during my recent absence from the country. Amongst the new parts I received was a pair of RGV250 throttle cables - the one that connects the twistgrip to the throttle cable junction box. I previously purchased a Domino twin-pull, quick-action throttle unit from Mead Speed as I need to control 4 carbs.
So I thought I would spend 20 minutes of yesterday connecting the cables to the twistgrip and the 2 throttle cable junction boxes. Except, as with all specials, it's never quite that straightforward, is it?

First problem is that the RGV throttle cables are too big to fit into the Domino throttle housing - it has 2 x 6mm threaded holes - the RGV cable is 7mm at the twistgrip end. Time to fire-up the pillar drill.........



with both holes opened out to 7mm, the next obstacle reared it's head. One cable would fit just fine, but the cast-in "flange" that prevents the cable from being pulled into the twistgrip ensured that 2 cables couldn't sit side-by-side. Breakout the files............



having mapped the cable routing from the twistgrip (to allow the in-cable adjusters clearance from each other) I proceeded to file a flat on each cable's "flange" which susequently allowed the cables to snuggle-up to each other, thus............



and, finally, 1 hour later than expected, it's fitted and connected..........



specials building? pah - piece of p*ss...............

[Suzukidave]

[garry55]

still waiting for the carbs, so a bit more bodging........

single tap fuel tank



with donor tank



which donated it's fuel tap mounting



now a twin-tap tank - 1 tap to feed each set of 2 ravenous carbs

[garry55]

still waiting for the carbs, so more bodging.......

how to operate 4 independant choke slides?

a browse on t'bay and I spied these, so bought a pair - YZF750 choke lever assemblies





stripped to their component parts



having discarded the redundant parts



and the finished assembly





this assembly will be mounted on the r/h frame spar and will operate standard RGV250 1-2 choke cables.
Mounting position to be decided when I get my carbs back from cleaning and re-jetting.........

[garry55]

more progress..............

the twin, four choke cable installation........





and the self-contained temp gauge.........



still a bit of tidying to do...........

[garry55]

put the pipes back on the V4..............



then set about wiring-in the Zeeltronic.........

[Suzukidave]

Nice and isnt wiring fun

[garry55]

very easy on the V4 Dave - it's not running TPS, air solenoids or p/v's for test purposes

[busa1300]

Did you get some stronger gears for the transmission since you have twice the engine now? Any foreseeable clutch issues?
Do you have your sprocket alignment all figured out yet?
A good running RGV will put 60HP to the rear wheel, so a possible 120 would make a wild little ride

[garry55]

I have a set of modified primary gears that spin the gearbox faster, thus reducing the torque loading on the box.
Clutch has RM springs fitted.
chain alignment was sorted before engine build was started.
should have 100bhp to start with - I reckon 130bhp is attainable.

[garry55]

the water pipes arrived today....................



pre-assembled..............





and fitted........

[garry55]

Took the Zeeltronic box off the shelf and dusted it down with a view to fitting it......



all those bloody wires ! and hundreds of sheets of gobbledygook about programming and mapping and 3D and........



a bit fazed by it all, to be honest, so I made good use of the free Tuning Works t-shirt that came with it......



did sort the oil leaks though - it doesn't bode well when it's only got transmission oil in it and springs 2 leaks......

[garry55]

oops - double post...........

[garry55]

it's been a long, long time since the V4 was relegated to the naughty corner, but here's an update at last.
I couldn't get a single spark with the Zeel fitted - checked wiring, charged the battery, bought new coils / leads / plugs, changed the pick-ups for known good ones and still zilch. Ran direct earths from the battery to the Zeel unit and coils but still no spark. Eventually, it was agreed with the proprietor of............



...........the amazingly helpful Mr Sean Hadley, from whom I purchased the Zeel, that it would be returned to Borut in Slovenia to have it's functionality checked at the factory. Today, I received a parcel from Sean which not only included this..........



..........the factory checked, Zeel but also this clever piece of kit.........



.............a signal generator - it plugs into the RGV loom and tricks the Zeel into thinking that the motor is turning over, so I don't have to physically kick it over to check for a spark. It's also programmable for how many revs you want to "induce", so would be ideal for verifying if a coil is breaking down under load, for example, as you can leave the plug(s) on top of the motor and watch the spark(s) whilst increasing the load via the revs adjustment facility.
Sean has also disabled the TPS, air solenoids and power valves functions within the Zeel so it's operating only as a basic ignition module for testing purposes. So, this weekend, I shall be mostly looking for sparks...........

[garry55]

how not to make an airbox for a hybrid V4 500................

the r/h side carbs are orientated correctly, but the frame gets in the way of fitting a VJ22 airbox.......



nothing a deft bit of hacksawing can't overcome........



voila...............



a bit more trimming................



and the fuel tank and tap fit................