Yamaha RZV500R <PULSAR> engine project

[Pasha]

O-rings came at last. Now I can finish heads drawings.

[Pasha]

Stock 100mm and beautiful Hot Rods 115mm.



Beautiful bottom honed surface ))))



Center webs from Yambits. Someone here asked if quality is good enough for such a low price?! No. While grinding and polishing pin got -0.01 (21.99) and because of not good enough balancing on the equipment while manufacturing pin had oval shape. You could see on pics. Else more 0.02 and pins are round shape )))))





The only way to get a gap 0.02 is to make new needles. Didn't find 11.8mm (length) needles, so regrind from 13.85mm. Needle cage should be reassembled and milled to fit new needles.

[Pasha]

New long studs to centered both interface plates and cylinders.



Modified PW rack.



SS exhaust springs.

[Pasha]

Hi fellows. Need your advice to clarify correct dimensions. My crank collars are 35.4mm despite oil seal is 35.00, and thickness 14.6mm. Does anyone have an opportunity to measure yours?

[Darrell]

How impressive! Thank you for the details and great photos, and good luck as you continue with this fascinating project.

[Pasha]

From my point of view fastest and easiest way to set 180 deg for my cranks.









Side bottom conrod clearance was changed to 0.75mm for better lubrication with the cost of dimension between central webs. Labyrinth seal is less in width for 1 mm as well.



Cranks are ready for installation, but can't be installed at a moment. Need your help with dimensions from previous post.

[steveho]

Hi fellows. Need your advice to clarify correct dimensions. My crank collars are 35.4mm despite oil seal is 35.00, and thickness 14.6mm. Does anyone have an opportunity to measure yours?

Right, i finally found my spare ones, and measured a couple, and they have identical dimensions (digital vernier)
OD, 35.00mm
Thickness, 14.57mm

Hope this helps!

[tacky1]

Very nice work. Looking forward to hearing her run.

[lost1750GTV]

!!! Serious stuff !!!

[Pasha]

Hi fellows. Need your advice to clarify correct dimensions. My crank collars are 35.4mm despite oil seal is 35.00, and thickness 14.6mm. Does anyone have an opportunity to measure yours?

Right, i finally found my spare ones, and measured a couple, and they have identical dimensions (digital vernier)
OD, 35.00mm
Thickness, 14.57mm

Hope this helps!

Thank you so much!!!! Finally I can go further

[Pasha]

[Pasha]

[Pasha]

Crankcase now is ready to receive cranks.

[Pasha]

New crankshaft bushings transmission side let me assemble the bottom end finally.

[Luther]

Good work, can't wait to see more.
I think .75mm side clearance on rods is good. In mini mx at .5mm they overheat. I'm guessing yours will get run on track.
What did you decide on the exhaust boost to piston pin hole? I don't think 1.5mm will be a problem