Nearly 3 years...disgraceful

Hard to believe that it's coming up on 3 years since I rebuilt the engine in the RGV and fired her up for the first time. Here's the latest clip of a little maintenance run the other weekend. I really need to get this on the road......

New Commuter - KTM 640 SuperMoto

Been another long while but I've picked up a KTM640 SuperMoto for the commute to work. Good fun but sometimes it does not go as planned as you can see below.

RGV is not far from being on the road probably by March next year if all goes well.

Pulled on the RGV

I took her out for a little test ride and it became expensive....

More motivation to get it on the road asap!!!!!!

WTF over!

Decided to fix the indicators today and what a debacle that turned into. I'm running led indicators and knowing you can't use the normal flasher I went off and bought a LED specific bike one.....and it didn't work. In looking at that the rear brake light was also no longer working???? Checked the light itself and it was fine, the brake pressure switch was playing up. Maybe I don't have enough pressure in the line?....Why is there brake fluid on the rear sets? FAAAARKKKKKK!!!!! Long story short, the brake switch is cactus - need a new one. The master cylinder has been leaking brake fluid past the reservoir attachment seal - need to replace the seal or replace the whole master cylinder. My uber sexy HRC race reservoirs are still sweating brake fluid plus the lines have clouded - have to consult with the seers at RGV250.co.uk for some advice on this one.

Went back to the original indicator flasher and decided to load up the indicators with after market resistors so it will flash - need to buy them.

One step forward and about 6 backwards....I hate having to revisit parts I've already "fixed" ;-)

Getting there...slowly

Fixed the power valves - I had the servo pulley on the wrong way which didn't help, so flipped it, then setup the top cylinders cables correctly and I now have working power valves. Timing them was pretty easy as I was expecting some sort of black magic ritual.

Off with the exhausts and in with the new gaskets and around the block for a quick spin, awesome. I'm supposed to keep it to 6,000 for the first 500 kilometers but couldn't help a quick excursion to 9,000 - just to check if the power valves were working of course.

What's left:
Time the power valves
Fix the indicators
Kick start seal is leaking
Front fork seals are leaking - and front feels pretty soft
Rear brake is ordinary - check pads
Tune the carbs
Sort out leaks from both exhausts
I'll be sorting out the electrics and then it's time to fix the leaks before it's off to Bogaarts for a dyno tune. and then rego.

One thing I have noticed is that the HRC reservoirs are sweating in the heat. I haven't come across this before and will need to keep an eye on it.

What's next??

The sticker kit has arrived and...I don't like it. The bike will not be a Rossi Camel replica. I've used the number plates and some of the sponsor stickers but will go with my original preference of Nikon and Racetech as "sponsors".

The replacement battery strap arrived from Tyga - cheers guys, appreciated you sorting that out for me.

I picked up the exhaust gaskets from Springwood Suzuki but will wait till I've got the power valves sorted out before fitting them. Speaking of which I worked out why the PVs wouldn't turn.....Power Valve motor was seized. Luckily I had a spare and have swapped it in - just needed to change the front cam and it's in there.......now to time them. I've got one very slightly frayed power valve cable and I'm tossing up whether to replace it or not.........

Sunday

More work on the bike:

Fitted up the key barrel, replaced the rear brake reservoir with a full size HRC unit. Put the old rear on onto the front which means I can get the levers where I like them. Topped up the coolant and gearbox oil. Hacked up a battery strap from a battery strap from a boat. And then.....took it out for a spin. It's everything a 2-stroke racer rep should be - light, easy to manouver, pulls well and the gearbox is great - shifts like butter.

Unfortunately there is a new list of things to fix:

Time the power valves
Fix the indicators
Kick start seal is leaking
Front fork seals are leaking - and front feels pretty soft
Rear brake is ordinary - check pads
Tune the carbs
Sort out leaks from both exhausts

...and there is more, getting there....slowly.

Saturday - IT'S ALIVE!!!!!!!

Up early and went to get the key cut....they've moved, after a quick spin 4 suburbs over they took an hour.....and no joy. Back to Tommy at MMM Motorcycles for the chain and luckily he had the replacement part for the carb. Aired the tyres on the way home. Back home, gave up on the battery or rather it gave up the ghost, quick run out and picked up a new one. Worked out the key myself. Fitted the battery, kicked, and kicked, and kicked and....nothing No spark, started chasing down the problem - corroded ignition fuse, kicked again and.....let the smoking commence!!!

Friday Night

Petrol in the tank, 35:1 premix - running Motul

Charge the battery

Bled the rear again

Broke the throttle adjustment on the carb putting on the airbox.....F**KING HELL!!!!!

Ready for tomorrow

Getting closer.......

We're getting closer and closer to firing up this little beasty.

Charging jack is in

Rear brakes are done

Tank being flushed and cleaned today

Key recut this Saturday

New chain as well

Petrol, air the tyres, gearbox oil, and coolant and away we go!!!!!

Should be a fun Saturday.

RGV hitlist gets smaller...and bigger

Some more achieved...and some more to do.

• Subframe re-aligned - Done


• Rear shock reservoir mount - Done


• Chain


• Power valves timed


• Refit exhausts and gaskets - Done


• Side stand switch and wiring - Done


• Extend rear wiring - Done


• Shift linkage machined - Done


• Mirror mount gaskets - Done


• Key re-cut for ignition
  

and some extras:

• Add charging plug to wiring


• Coolant


• Setup rear brakes


• Mount rear shock reservoir


• Flush fuel tank

A little update

Okay, finally got around to doing some more work on the RGV.

The clipons and levers are on. The grips don't fit so off to eBay they go.


Dan has come through with the shift rod and wasn't it a saga getting the reverse thread cut but it's on there now and that's one more thing off the list.

And to cap it off I have sold my GSXR1100 as well. Sorry to see that one go especially after the amount of money I put into it over the last 2 years but the Harley had to be paid for. One benefit is it frees up some time to focus on the RGV.

Controls have all arrived

eBay hath provided all the controls so now it's time to get it all on the RGV. Dan's machining the shift rod and then I can finish the foot pegs and controls. Getting closer............ Oh and the Gixxer is up for sale on evilBay again.....

Harley circuit breakers are no more

I'm still waiting on the clipons to arrive so in the meantime I removed the circuit breakers from the Harley and replaced them with fuses. Hopefully it won't cut out on me again. I also got some of the security stuff sorted out so all in all a good Saturday.

Control makeover

After sizing the clipons incorrectly I've orderd in a new set in......gold


And a set of grips to match in.....gold

And a set of shorty levers in.......gold




I love Goooooold!!!!!!

On hiatus

Not much happening for a while - my son Brendan is just out of hospital after a 2 week visit. Be a while before I get back into it. Having said that I sneaked 20 minutes to myself to mount the new Pazzo-style levers to the RGV. The Harris clipons I got are the wrong size - should be 50mm and I bought 52mm. DOH!!!!!!! I measured too far down on the fork tube.

The Gixxer didn't sell on evilBay even after 2 attempts so the steering damper is back on it and I'll keep the bike for a little while.....oh and I got a speeding ticket....in my wife's car.

Progress continues

The Tyga rearsets have arrived for the RGV so they're now on and the pipes are lining up correctly. We've now marked the cans so they're straight when on the bike and the mount plates and pipes are with Dan to be welded and the ends re-chromed. The replacement Tyga carbon fibre hugger arrived along with another HRC rear brake reservoir race kit. No pictures but we're slowly getting there - Still needs:

• Subframe re-aligned
• Rear shock reservoir mount
• Chain
• Power valves timed
• Refit exhausts and gaskets
• Side stand switch and wiring
• Extend rear wiring
• Shift linkage machined
• Mirror mount gaskets
• Key re-cut for ignition

The Harley still has a few electrical gremlins in there which I am trying to work through but it's a bit of a task to get them all. I had a few more rides so I'm slowly getting used to it now.

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.

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.

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.