Fixing the Harley

I've shortened the headlight mount bringing it in closer to the forks and mounted the speedo off to the side. Chasing the wiring fault has been an absolute saga with over 20 solid hours into finding the problem and fixing it. After a lot of work I narrowed the all flashing indicators and no brake light problems to the rear of the bike. I spent a while chasing a bad earth only to work out it was a complete short on the back of the bike. Sounds easy to take out the wires in the fender and sort the problem? Unfortunately no..the wires had shorted and fused their insulation together into a solid plug and it wouldn't budge even with a coat hanger rammed in there. I had to grind out the tube the wires run in just to get it out of there...and then re-wire the rear end.

Anyway, it's fixed now and I have indicators that behave themselves and brake lights that work.

Gixxer engine work finished

I got my GSXR1100 back from Tony the other weekend. Great fun to ride it back in one of those sub-tropical torrential downpours. Dan (aka The Wolverine) enjoyed his "shower" on his new XVS1100.


We've upped the Dynojet kit on the GSXR from a stage 1 to a stage 3, added K&N pods, and dropped a tooth on the front sprocket. Gained 2hp on the top end (now 127bhp at the rear wheel) and another 7hp through the mid-range. It goes like the proverbial now and is an absolute blast to ride.

It's really killing me to sell this to pay for the Harley......I don't know if I can bring myself to part with it...

Is very....nice

Got it back from the mechanics early this morning and I've fixed the digital speedo (replacement magnet in the rear wheel), and broke the speedo houseing at the same time (needs to be re-tapped). The headlight is apart to shorten the mount, the indicators now flash (all 4 of them at the same time), the brake light still doesn't work, and it's already leaking oil on my garage floor......oh the joys ;-)

Bought a Bobber

I'm very happy with my latest purchase - Harley Bobber. After the failed start that was the Oompa Loompa Chopper and looking at Yamaha XVS1100 bikes I held out and went with the original and bought a Harley. My first foray into Harley ownership....see how this goes. This means the Gixxer is going up for sale after Christmas.

Rearsets are on the way

I ordered a set of Tyga rearsets and another carbon hugger for my GSXR. The new tyres on the Gixxer are great and provide a lot more confidence. Once the rearsets are on the RGV I can fit-up the exhausts and start welding.

New tyres on the Gixxer

The old sports-tourer hoops on the Gixxer were not giving me the feel or confidence I wanted from my tyres and I'd reached a point where I wasn't confident to tip it in too much. Mick's tyres had a special on a set of Dunlop GPR-a11s and.....it just happened.

I'll see how they go on the bike ride I'm organising for this weekend, but they're already an improvement and I haven't even finished scrubbing them in.

Pipes are on and fouling

I got round to trial-fitting the pipes so I could have the cans welded on. fitted them up okay but one is fouling on the rearsets.


So I can't line up the cans.

I've got two options - take a hammer to the expansion chamber to give it some "remodelling" or get a new set of rearsets. Had a think and I'll be getting the new set of rearsets.

New mirrors are here

I ordered in a set of CBR2250/VFR400 mirrors and they have finally arrived . I'll put them on soon and post up a pic. Need to get onto RGVSpares.com and get my parts organised to finish this thing.

Trial fit

Indicators are on (cables need to be extended), seat is on, fairing is on....and the subframe is canted to the left. @#$%ING THING!!!!

Will just have to come off again and be "persuaded" to line up properly.

Onto the zorstssssssssss

I need to get these collars off so the end cans can go on

Hello Mr. the grinder

And Mr. the flap wheel - ready to weld.

New exhaust for the Gixxer

The old Micron carbon fibre can on the Gixxer has finally broken one too many times. I headed over to Motorcycle Exhaust Professionals for a repair and bought a GP style exhaust instead - a bit more than I wanted to spend but it looks and sounds great.

New indicators

I've ordered in a set of LED indicators so will have to wait for them to arrive from the factory of the world - China. No word on the shift connector will chase Deet at RGVSpares again. I'm stuck on how to route the remote reservoir for the shock. The line just doesn't lend itself to anything that looks good.

Had a little break

I've had a little break from working on the RGV and focused on some poker and archery but I'm itching to get back into it. I'll need a new shift connector so will check if rgvspares.com have one and also hit up my brother in law for a machined linkage rod.

Chipping away

Not a lot completed this weekend, I'm still working on the wiring, have the undertray in place, it was a tight squeeze into the frame and now has a hairline crack - not big, resealed, and not noticable. Trial fit of the oil tank - I'm in two minds on whether to use this or stick with pre-mix. I took off the rear master cylinder and managed to collect most of the air bubble in the line, quick bleed and it's back on but it still needs another bleed to finish off.

No work done....but...

No work done on the RGV this weekend although I did work on my other bike. Heading to a mates house it dropped onto 2 cylinders half way there. Getting back home I narrowed it down to the 2 centres so checked the power to the 2 coils and it was all ok.



??????......and then I found this detached from the right coil...........quick solder job and we're back in business.

Progress

Some more progress with the carby's now plumbed. The interference hoses were a pain so I went back to the originals with no drama. Front fender is on and I tried the tail on for size. I'm very happy with the way that Simca painted the tail: http://www.simca.com.au/. Still a ways to go: indicators, rear wiring, fit exhausts, weld flanges for the cans, tail-light, plate holder, time the power valves, flush the tank, rear fender, ignition key cut, machine up shift rod, bleed rear brake, make sure the wiring is all correct, chain, air box, oil tank or pre-mix?

Tyga tail is painted

The tail is painted and on it's way home to me and the fuel hoses are bought (cheers Dan). Radiator hose T-piece is on the way from RGVSpares.com - better than Suzuki's 3 weeks in from Japan.

Motor's in!!!!

Got busy on the weekend and after a lot of grunting got the motor into the frame.

Offer the motor to the frame (like my engine jack?)


Put out your back in the process of lifting it in


Voila. Cradle on and commence the plumbing


This is starting to look more like it.


The cooling hoses are all on but I'm missing a T-piece I have to order. Hooking up the wiring was actually pretty easy based on the layout and coloured connectors. The cable control box was a doddle if only the same could be said for the power valve cables but they are all connected (after only one tantrum) and now just need to be set up. Time to call the painters and see if they've finished the tail section.

Engine is together

The missing parts arrived for the engine and it's now all torqued together ready to have all the ancillaries put on - I'm not looking forward to the cable spaghetti that is the power valve control system.....I'm glad I have the manual.

Engine is together....almost

A late night wrenching on the motor.

First RTFM

Pistons on:


Barrels on


And finally the heads

So I've got the pistons swapped out, cylinders on and 1 head....I'm missing a dowel and washer so will have to source some more before I can button up the last head. A quick flick of the starter and everything was turning fine, except for the starter. I'm not getting full engagement on the kick starter through it's travel. It can wait till the motor is together and I'll look at it then.

Busy, busy, busy

A busy weekend with the Tyga tail off to the painters and a new battery bought. I spent a bit of time setting my GSXR's suspension back to a neutral setting front and rear and gave up on the low air pressure and pumped the tyres up to 36 front and 40 rear. It already feels great and is a big confidence booster in the handling department as the front always felt a bit vague before. I spent an hour and a half bleeding the RGV's rear brake with little success so I've got to take it off to flush out the air bubble that must be trapped in there somewhere. More old stuff sold off and the shed part redecorated. Now just to wait for the postman to arrive.......

Race bike is sold

The race bike has now been sold as well which leaves a lot more room in the garage and more money for the RGV. I've just placed the order for the piston kit and some Tyga end cans. I'm glad to be getting some momentum back on this. Now I need to find a good painter to colour match and paint the rear.

Carbs are on

A small bit of progress. I've got the carbs on after a lot of heaving and swearing to get them into the rubbers.

The pro bolt kit is in as well and I also swapped out the 14 tooth sprocket that came with the motor for a 16 tooth - see how it goes on the road.

Oompa Loompa chopper is no more

The dream that was the Oompa Loompa chopper is no longer with us - in fact it went to Toowoomba in the back of a van, sold on the evilBay. I have too many projects keeping me from the RGV so out it went. The race bike is also for sale and I'm flogging off a load of spare parts as well so the coffers are filling back up to finish the RGV.

Some (small) progress on the racer

I've fitted the blanking plate for the thermostat on the racer. As the KLX650 motor already has a thermostat in it I've removed the extra one that was a left over from the original RGV plumbing. I'm still saving for the pistons and rings so progress is slow.

I went out on a club ride to celebrate one of our member's birthday (Happy Birthday Ross). I spent most of the time cruising and being passed by the faster riders but it was fun all the same. This is about as close as I'd like my Gixxer to be to a Highway Patrol car......

When bolts go bad

The new pads on the GSXR were nice...the missing bolts in the rear caliper were not. With a ride on Saturday I managed to have my bike squeezed in at the local mechanics for an all round pad change before I went to work. Heading out to one of our suppliers I found my caliper hanging off with one bolt gone and the other one halfway through backing itself out. I'm glad I was cruising in the burbs rather than on the highway. A bit of bush craft with some cable ties (thanks Craig) and we were back in business.

Ultralite Bobber aka Oompa Loompa Chopper

I couldn't resist.......another fun project has risen from the ashes. This is the rolling chassis from the donor bike. Most of the parts have been stripped off and put on the other 2 bikes I am building and I was left with these parts scattered around the shed. A quick twirl of the spanners and they're all back together and the wiring loom removed. The original subframe has been cut up and redone to get the seat height lower and further back.


Thanks to Dan for welding it all together.


The aim is to get together a mini bobber with a nice simple air-cooled motor in there. Next up are the handlebars and after that the search for a motor that will fit.

Barrels are ready

I finished the barrels over the weekend which leaves me scraping the money together for a rebuild kit - pistons, rings, and gaskets. While I'm doing that I'll continue working on the race bike and start finalising the 2 strokers wiring.

I've also been looking around the place at.....dare I say it Harley Davidsons....especially bobbers. The old clean ones are great and I like the look of a lot of the Japanese efforts.



Harley's sure hold their value well as backet cases are at least $4500 before they're even touched. Cruising the interwebs got me onto the XS650 style bobbers and choppers and there are a lot of cool bikes around. This got me thinking to using what you've got which is much the way the old bobbers and choppers came about. What have I got? Well I've got another RGV rolling chassis....I wonder......



An XS500 motor in there.......? Do I have enough projects yet?

Been a while

It's been a while but I've had my Dad over from Ireland, we've both been working on the shed, and.......riding my other bike. I got into the RGV motor while work on the other bike takes a break. Power valves are out and the barrels are off.


One of the barrels had a lot of scoring in the power valve guides (below) so I've cleaned up one from the donor bike instead.


Next step is to put the power valves in both and decide on whether to replace the pistons or just do the rings and put it back together.

Steady progress

I've kept ticking along on the racebike over the last 2 weeks. Although I was going to focus on the RGV first I've been picking up the smaller low-cost items on the supermono before it gets to the expensive parts and will be shoved in the corner.

All of the wiring is complete, grips are on, and the plumbing is almost done (picture to follow). The tank has been a problem as the underneath needs to be modified to allow for the carby and water filler. The original was set up for this but the tank itself was in a pretty bad state with rust and dents. I've cut out the bottom of the tank to leave the top as a skin for a fuel cell to be mounted in underneath it. Hopefully this will work......

Before

After

I also got in a little spin up Mount Glorious on the Gixxer. If you want the place to yourself then go when it's raining ;-)

A few small things..........

I'm still picking away at the edges of these bikes. The braided line is on the Gixxer but needs to have one of it's mounts re-done as I was missing a grommet. The heat shrink on the ends was a bit of a pain for routing and it would look nicer without it. At least there are no more leaks.


The benches are in with the aluminium tops in place - all ready to be scratched. I've even put one of the RGV engines up on top (you can see it in the background).


I've finished polishing the Supermono's replacement fork legs but I couldn't get all of the scale marks out of the metal so they'll just do as they are. The clipons are on the bike with the mount for the key barrel cut off.

Before



After

I have a feeling the forks are too far through the clamps and will need to be pulled back otherwise it will just be too nervous to ride. Which reminds me I need a steering damper.......Grips and new levers are ordered and on the way.

Seeing as I was in a chop chop mood the hangers for the pillion pegs and exhausts have been cut off as well.

Before


After



And trial fitting some RGV bodywork on the supermono



And the front bodywork off the donor bike will do for track days before I race it (hopefully). I'll need a dash as well.....


Trial fit of the bling on the petrol tank. I'm organising for the bottom of the tank to be cut out and then a fresh plate fitted up that won't foul the KLX650 engine/carb.

Workshop essentials

It's not strictly bikes but I finally got the bench and a bargain at $40 for the lot below. I should be right to start work on the RGV motors soon although it would look better with a steel top.........

And to enhance the ambience in the shed - a stereo!!!!

Picking the lot up tomorrow night.

Rear Master cylinder

Nothing very exciting lately - I cleaned up the spare master cylinder that is going onto the supermono. Everything seems fine, the little dust boot has seen better days but will be okay for now. Unfortunately the rear caliper was worse for wear and may need a rebuild kit.