New footrest holder

As the title says, got the CNC machine out and knocked up a new footrest hanger to go with the new gear lever. it's just so cool to have a CNC machine in your garage (ha ha ha...)

Clutch update and gear lever

It's great to have some time during the Xmas holidays to work on the bike. There is not even much snow, so I am not tempted to go skiing much.

Todays job was to install the new (thicker and stepped) thrust washer in the clutch. This was made by a guy on the RGV250 Forum in the UK, and he made up a batch, it is supposed to give increased lift to the clutch plate thereby allowing the plates to free up, it is also stepped so that it doesn't get worn on the bearing surface.

Anyway here is the clutch, all the plates and disks were measured and are easily still within service limits. They measured on average 2.85mms thick and the clutch plate claws were 13.96 mms wide.

I also made up a new gear lever, calculated to give more gear shaft movement for less boot movement, I am trying to fit it so that there is not as much play as in the old system.

Next job is to make new radiator mounting plates, and fit the new rad.

Decisions, decisions....

So, after measurement by my tuner, it would appear that my pistons and cylinders are at the limit of needing a rebore - at least one cylinder will require reboring. So for my peace of mind I am going for the rebore, however the stock Suzuki pistons are really expensive, and the tuner has a couple of options :-

Either I go for a full 570cc upgrade, this means boring out extensively the stock cylinders and fitting 60mm diameter pistons. This gives an extensive increase in mid range, and a little bit at the top end. The other option is to go for a rebore using CR125 pistons. This has the advantage of only "using" one rebore size, but also these pistons only have single rings, and therefore will have less friction. The biggest advantage is that I will still have loads of cylinder left for additional rebores later on.

OK decision made - I am going for a rebore with the CR125 pistons - I hope it still runs OK with Honda parts in the engine!! (in fact the pistons are made by ProX, but still made for a Honda dirt bike).

Technical Update

Well, my engine parts have safely arrived in the UK, only took 2 days, which this close to Christmas was surprising! I have fitted the racing rear brake fluid reservoir on the bike - which will probably win me at least a couple of seconds per lap.... :-)

2010 Calender on-line

First looks at the 2010 calender are impressive, with 3 big name circuits on the timetable. Time to book your holidays.....

- 27 and 28 March - Le Mans
- 8 and 9 May -  Croix en Ternois
- 5 and 6 June Nogaro
- 26 and 27 June - Magny-Cours
- 10 and 11 July - Pau-Arnos
- 11 and 12 September - Croix en Ternois (with the 2nd endurance "Grand Prix Classic")
- 16 and 17 October - Ledenon

Top End strip!

Well, I got down to stripping down the top end of the RG this weekend. No particular difficulties, it's interesting to see the different technical solutions Suzuki have compared to some of the Yam stuff. For example the power valves on the Yam invariably leak slightly, and yet Suzuki's don't and its a very simple design, and very easy to dismantle. 

Anyway the pistons and cylinders are in reasonable condition, no scrapes, no detonation, so I will need to make a decision on whether or not I get them rebored anyway. I have been in contact with M. Dent who is another reknowned tuner of RG's and he can do a 570cc conversion, or fit RG125 pistons which have single piston rings (decreased friction) which could be a good compromise, anyway I will pack it all up tomorrow, and send it off, and hopefully he will be able to advise on the best course of action to gain the maximum power whilst remaining reliable.