Yamaha RZV500R <PULSAR> engine project

[Pasha]

Hi fellows!!!
At last I decided to make a topic about my own ideal Yamaha V4 engine view.
My project goes slowly, unfortunately, but, nevertheless goes.
I hope it'll be interesting for YOU.



It has begun after oil pump failure. As we say "that is break - all for tuning"



My crankcase is dead and will take part in pilot modifications. Used but in good condition was bought from <miyabeepluscoltd-jp>

http://www.ebay.com/usr/miyabeepluscoltd-jp" onclick="window.open(this.href);return false;

The first step was sanding. I fond of working with sand details. To avoid oxidation I'll paint it clear varnish to leave "GP" view.
VHT SP145 Engine Enamel Gloss Clear Can













Piece of art

[rd84]

Nice to see your progress on this engine re-build.

Cheers
Paul

[Pasha]

I wanna thank to 2t-special.it & rzrd500.com forums for my inspiration. Thanks a lot.

So, the beginning of every engine is a crankcase. Truly saying, the basic engine concept was born quickly. But lots of time I spent while thinking about different little things. Cause I really know how much time these little things could steal.
Honestly, I don't like the intake at all. I can't understand Yamaha. How could they screw up OW76 and made THIS (((
And I'm gona fix it. ))) By the way, I think that intake in this engine is the narrowest place that decreases performance.
I choosed Honda NSR 250 reeds. I wanted Rgv/RS 250, but there is not enough space.



I wanna leave YPVS rack, so firstly I made a berth for reel axis.



Firstly I milled damaged crankcase. It showed me a weak places, such as pointed.



Using an aluminium <Devcon F> I filled them.







The next step was crankcase reeds housing milling.









I'll use longrods +15mm to recieve conrod / stroke ratio higher then 2.2: 115/50=2.3
In such case engine became smoother and could utilise high rpm for a long time with no damage. So, as YOU understand, displacers should be made. It's not their finish view, they will be smoother.















So, take a look to the preliminary assy.

[WVWRZ500N]

Could you elaborate on how you determined that the oil pump failed? Please describe the state of riding when the damage occured, i.e. speed, RPM, how many miles/kilometers on the engine?

Regards,
Bill Wilson
Wilson Performance
Lee's Summit, MO
http://www.wilsonperformance.net" onclick="window.open(this.href);return false;
Member RZ500 Owners Group #573
816-377-3185
WVWRZ500N@aol.com

[Pasha]

Could you elaborate on how you determined that the oil pump failed? Please describe the state of riding when the damage occured, i.e. speed, RPM, how many miles/kilometers on the engine?

Regards,
Bill Wilson
Wilson Performance
Lee's Summit, MO
http://www.wilsonperformance.net" onclick="window.open(this.href);return false;
Member RZ500 Owners Group #573
816-377-3185
WVWRZ500N@aol.com

Oil pump was not bleeded. Engine utilised oil in premix. And after break in 600 km I didn't add oil in to the fuel and it happened.... Unfortunately....

[Pasha]

Time for piston intake. There is nothing complicated. Just several pics of process.

[podman]

Wow, amazing work my friend, I wish you all the best with it, keep us updated.

[Pasha]

As it is common for me - I made templates for upper and lower cylinders.
I think safety thickness limit for scavenging bridge is approximately 4 mm.

Heads will be CNC. There is not enough place for outer o-ring. I decided to weld around the top of the cylinders.

[Smoker]

Just mind-blowing what people have done with this engine!!

Good luck with your project.

Can hardly wait to see more!

[Pasha]

A few words about portmap. It's horrible. Point.
Nothing could be done with OEM to be nice for me. Scavenging windows shape, horizontal, vertical angles... horrible....



New cylinder sleeves should be made to get admissible portmap.



I know that YOU could say that it's easier to install RGV/RS 250 cylinders.... But it's new question with YPVS... I already have stock cylinders, so I'll work with them.

[Pasha]

I had destroyed one cylinder. And it fell as a victim for the experiments. As YOU could see, after sleeve cutting out - groove could be seen.



And blank for the boost exhaust port.

[Pasha]

Power valves should be modified to give an opportunity for making exhaust boost ports.
Here YOU can see how and utilizing what gaps they are in stock.







Honestly, i was thinking about this part for a rather long time. And in the end I came to such a decision.
Valves should be elongate by washers. Blank clips should be shortened. Open clips should be made anew.
Heat them up and easily get out.







Weld grooves.



Weld washers.







Golden treasure with no boost exhaust channels at a moment.

[Pasha]

The blank for new YPVS rack.



New labyrinth seals (not finished).



New pump gear instead broken one.



Blanks for cylinder heads and cylinders spacer plates.

[wolfgangh]

Your engine mods are pretty similar to my race engine. Crankcase stuffers, longer rods, big reed cases welded on, exhaust boost ports, milled heads...
What modifications are you plannign for the cooling circuit?

[Pasha]

Your engine mods are pretty similar to my race engine. Crankcase stuffers, longer rods, big reed cases welded on, exhaust boost ports, milled heads...
What modifications are you plannign for the cooling circuit?

Yes. Your project inspired and inbreathed me, Mr. Wolfgang. But please note that it's not copy/paste. I'm going on my own way. Cooling circuit is an interesting part. Don't wanna open cards at the moment, touch wood.
All I can say - is stock mechanical water pump and larger radiator.