RGV500 Conversions
Decisions, decisions..........which motor shall I put in, I know the
dirty one!
Step 1: Strip down to bare frame |
Step 2: Remove the upper mounting lugs |
Step 3: Loosely fit engine using Mounting kit
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Step 3: Loosely fit engine using Mounting kit
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Step 4: Weld
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Step 5: Rebuild bike, fit motor
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Exhaust Manufacture
Now the motor is fitted, the pipe routing has to
be sorted out. This is done by laser cutting sheet steel profiles of the
finished exhaust shape and taping to the bike in the correct position.
Profile to check pipe routing |
Pipes tacked together
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View showing #1 stinger exit
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First stinger fitted
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Lower pipes roughly fitted before welding
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Another view
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Pipes are designed fit within the seat unit
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Top pipes rolled and tacked together
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Sub-frame lower rails removed and seat support fitted
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Top pipes now fit within the seat unit
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Four pipes fitted
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Side on of the four pipes
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The subframe will be remade in ally and will include the oil tank
and battery box, the original frame has been used just for jigging
purposes only.
Pipe manufacture will come to a stop now so i can concentrate on
building the motor. Once the motor is finished i can re-fit it and
then finalize end can position to suit. Jigs for these RGV
conversion pipes will then be made so i can remake these pipes for
anyone who is undertaking a RGV500 conversion project. These pipes
are to the exact same spec as the pipes i run on my bike and have
not been 'de-tuned' in any way.
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Pipes finally welded together
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Exhaust flanges, 'O' Ring type fitment
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Rebuilt & tuned motor.....120bhp RGV250 ?
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New Aluminium Rear Sub-Frame
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Rear Silencer Tie
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Side Silencer Tie
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Four Pipes Fitted
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Four Pipes Fitted
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The Best View In Motorcycling
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Oil Tank Fabricated
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Oil Tank Fitted
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I made a bracket to hold the coils, CDI and SAEC
controller
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Coil mount fitted, SAEC mounted under the plate |
Battery box cut and folded
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Completed ready for painting :o) |
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