Track bike progress

Got a customizing or restoration project? Post your progress pictures and updates here

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wolfgangh
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Re: Re: DIY Bike starter / engine first start after re-assem

#91 Post by wolfgangh » Wed Jun 29, 2016 9:19 am

Yesterday I started my track bike with the race engine first time after the rebuild caused by sand being sucked through the carbs into the crankcase. Since the bike does not start easily by kickstarting, I have built a starter machine by use of a car starter. I have seen similar starting devices being used by DUCATI in MotoGP and also in Kart racing.

Bike ran well, carbs need better synchronization and are pretty rich at low RPM (which is OK, it will not spend much time at these RPM on the track). Need to fix some minor electrical issues, like PV servo closed position readjust, and one of the temp gauges behaves crazy.

Here are some pics of my starter machine and below a Youtube-link:

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And here in action:
https://youtu.be/On-E5qIwiMg
Last edited by wolfgangh on Mon Sep 11, 2017 4:41 am, edited 2 times in total.

Dubsey
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Re: Track bike progress

#92 Post by Dubsey » Wed Jun 29, 2016 10:42 am

Love the music on the video :smile:

Italy next year ?
Mediocrity is a sin !

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Smoker
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Re: Track bike progress

#93 Post by Smoker » Thu Jun 30, 2016 2:20 pm

Love the starter you made!! :cool:

Thanks for sharing.

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Re: Track bike progress

#94 Post by Dani » Fri Jul 01, 2016 5:51 pm

Hi ns86 the company is Motorquality, distributor of Brembo

HWY9CA
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Re: Track bike progress

#95 Post by HWY9CA » Mon Jul 04, 2016 12:22 pm

Very Nice re-build- cool starter!!!!
Thanks for the video.

JT
http://www.rdsonly.com/
JT
1975 RD350B
1975 RD250B -rough
1979 RD400 Race bike- in process
1985 RZ500 - flame bike
1993 TZ250 4DP2- to be restored

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wolfgangh
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Re: Track bike progress

#96 Post by wolfgangh » Sat Jul 09, 2016 4:32 pm

Today was D-Day - first Dyno Day with our Race Engine.

We went to a good friend of mine, a real 2-stroke nut (and board member) who purchased a Dyno 2 years ago just for himself - he has no professional workshop but uses it just for himself and friends. The software is pretty archaic though (does not even allow to export data) but the results seem to be very reliable, at least accurately reproduceable, meaning the same bikes gives very identical results and curves if dynoed on different days.

My RD500 race engine is currently running RGV250 carbs with an eye-balled base jetting only, ZEELTRONICS CDI and JL pipes made to our own specs.
Here is the bike prepared for the dyno run:

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We made a few heat cycle runs under load first, not revving more than 6k RPM to begin with since the motor is freshly rebuilt after the desaster with the sand being sucked into the crankcases last year, and increased max. RPM after each run.

Then the moment came of which I was so nervous about during the last 5 years- the moment of truth. It could have become a desaster if the result was only 85RWHP or so...after all these huge efforts and $$$ we put into this engine project.
I could not look at the screen during the run - I was too excited. I only saw a big smile on my friends face when he let the bike roll out on the dyno.

Here are the results (these are rear wheel figures):

113,9HP @ 10,050 RPM
80,5 Nm = 59 ft-lb @ 9,790 RPM

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For comparison we are showing the results of a friends RG500, with Jolly Moto pipes, prog. ZEELTRONICS CDI and higher performance disc valves. My bikes curves are in blue, the RG500 is in red.

Here the power in RWHP:

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And here the torque:

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Remember, my bike was not dialled in at all, it was a baseline setup without any prior experience. As you can see, power fell off a cliff after 10,000 - we dont know yet whether this is based on the ignition timing or the pipe layout. My jetting seems to be very rich still, based on the huge amount of oil in the silencer tips even after the full run. We dont have an O2 (lambda) sensor available to analyze mixture.

Here are pics of the silencers after the run:

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Unfortunately I noticed an oil leak after the run, gearbox oil was dripping out from behind the clutch basket of my dry clutch. I hope I can find the reason for the leakage soon - it only leaks at higher RPM, either due to increased gearbox pressure or due to vibrations.

My resume after this day - not even in my wildest dreams I would have expected to start the engine dialling-in from a baseline of 114 RWHP. With potential to improve further with ignition curve, jetting, pipes. Brian Turfrey - its your time now!
Last edited by wolfgangh on Mon Sep 11, 2017 4:46 am, edited 1 time in total.

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Re: Track bike progress

#97 Post by gpaddict » Sat Jul 09, 2016 11:27 pm

Awesome job Wolfgangh, so excited for you!!!!!!

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hybrid
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Re: Track bike progress

#98 Post by hybrid » Sun Jul 10, 2016 5:32 am

Nice work mate.
Many people speak of over 110HP from these engines, but not many prove it.

rd84
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Re: Track bike progress

#99 Post by rd84 » Sun Jul 10, 2016 7:25 am

Congratulations Wolfgang - really pleased for you - thanks for sharing your story as well - its interesting and inspiring to read.

Cheers
Paul

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Re: Track bike progress

#100 Post by RZColinPaul » Tue Jul 12, 2016 3:36 pm

Nice looking bike Wolfgang, It looks fantastic. What reeds did you use and were you close to a Yamaha TSI spec porting. You have motivated me to get my build finally done. Will you have a video that we can all enjoy soon. !!!!!! :smt006
colinpaul@rogers.com
RZ350 race bike
RZ500 stock
RZ500, TSI spec factory tune stage two,ported polished,JL pipes,28m Mikuni carbs,EB brakes, R6r front end, R6r swing arm, YZR fairing, V Force reeds, Olhin shock, Wasp Performance

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Speed Freak
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Re: Track bike progress

#101 Post by Speed Freak » Tue Jul 12, 2016 6:24 pm

Very nice result.
I want to see this bike in action :smile:
Will you be at the Hollaus Gedächtnisrennen this year?
My bikes:
RD500 YPVS 1GE
RD350 YPVS 31K 1985
Honda CBR 1000 RR SC57
Yamaha R1 RN04

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wolfgangh
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Re: Track bike progress

#102 Post by wolfgangh » Wed Jul 13, 2016 11:44 am

RZColinPaul wrote:Nice looking bike Wolfgang, It looks fantastic. What reeds did you use and were you close to a Yamaha TSI spec porting. You have motivated me to get my build finally done. Will you have a video that we can all enjoy soon. !!!!!! :smt006
Hello Paul,
here is the porting of the cylinders, I dont know how this compares to the TSI specs.

Please note that there have been many more modifications done to the engine, like:
longer conrods, crank inserts, crankcase stuffers, billet heads, 34mm carbs, modified reed cages with V-Force Banshee reeds, lighter flywheel, ZEELTRONIC progr. CDI&PV controller, dry clutch, 2 independant electric water pumps, etc.

There is a separate thread you can follow the engine build:
http://www.rzrd500.com/500phpBB3/viewto ... =3&t=11729

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wolfgangh
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Re: Track bike progress

#103 Post by wolfgangh » Mon Aug 29, 2016 4:32 pm

Some updates on the engine front. Made another few dyno runs with minor changes in ignition and PV curve to last time, changed main jets on upper cylinders.
Main purpose for today was to see if the dry clutch stopped leaking oil under full load - and yes it did not leak at all!

Power increased to from 113,9 to 116,1 RWHP and torque from 80Nm to 85Nm - a significant improvement for that little chnages!
The engine still runs way too rich, EGT was only 540°C front and 500°C rear. There is a couple of more HP to find in correct jetting, and exhaust pipes of course.

Image

Here a video:

Last edited by wolfgangh on Mon Sep 11, 2017 4:47 am, edited 1 time in total.

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wolfgangh
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Re: Update - Track bike progress

#104 Post by wolfgangh » Tue Aug 22, 2017 5:04 pm

Long time no post - I have ben busy with building my SUZUKI GT750 powered BIMOTA HB1 replica, and restoring a KREIDLER and a HONDA SS50Z Moped.

While waiting for Moped parts coming back from powder coating and painting, I fiddled on my RD500 Rainey trackbike to improve carb setup. Changed mains from 320 to 310, and needle jets from O-9 to O-7 (in separate steps of course). Max. power increased to 119,1HP , torque is 85 Nm, and leaner needle jet made midrange worse - will go up with needle jet to P-2 next time.
Since EGT is still well below 700 deg C, will also reduce mains to 300 next.

It is very conveniant to have a good friend with his own private dyno and always being willing to help out.
Mission 120HP will be completed before end of the year.

RC45
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Re: Track bike progress

#105 Post by RC45 » Tue Aug 22, 2017 5:20 pm

Looking good!

What sort of temps are you looking for?
CBR1000RR SP2 HRC WSBK
TZ500V/OW53 Track bike
YZR500 OW81 Clone
OW69 Daytona 200 Replica - 784cc Monster
NS400 Track Bike
RS250R NF5
TZ250T 2KM
TZ250B 3YL
TZR250 3MA Track Bike
427ci C5 Z07

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