RD500LC and FZR400RR project
Page 2
03/11/2005 to 11/11/2007
I've recently bought an FZR400RR type 4DX / 1993 in order to make a nice alloy framed RD500 for track day runs.
In
this page I will try to give news from my
project.
Last
step
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Photos (click to enlarge) |
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My RD500LC with complete YAMAHA FZ750 front end (see previous pages for details) : wheel 3 x 17” with 120/70x17 BT45 front fender brakes (rotor & calipers) 39mm fork with preload adjusters and 250TZR clip-on |
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03/11/2005 I've removed the FZR400 coil bracket. These are very nice so I think I'll use them for my project. I've installed the coolant bottle to check the assembly (I'll need to grind the frame plate on 3mm). |
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15/11/2005 Still waiting for the front sprocket !!! I'm looking for an upgrade for the rear shock, this could be an FZR400RR - Sport Production shock on ebay (left image) which is adjustable in preload, rebound and compression. The standard one is on the right image. |
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19/11/2005 I've found that YZF 750 shock has the same mounting as the FZR400RR one. I've bought an YZF 750 shock from ebay in the UK. This shock is adjustable in preload, rebound and compression not like French YZF shock. |
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11/12/2005 As the front sprocket does not come, I've canceled the order and make a new one at Blue Oil France on line shop |
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13/12/2005 I've purchase from ebay in the UK a Top end gasket set made by Vesrah (Made in Japan). You can check the international site for more details. |
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17/12/2005 Blue Oil order arrives, I confirm very good on-line shop. Front sprocket JT : 1579 - 16 teeth Rear sprocket JT 846 - 39 teeth |
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29/12/2005 I've made the lower and the front mounting bracket for the engine this allows to remove the link. Thus the front sprocket alignment and the upper pipes clearance can be checked. I've also shortened an old 520 chain from my DTR 200 this will help for the front sprocket alignment but also to know how many links I'll need. |
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30/12/2005 I've made a second version of the bracket which allows move the engine 10mm up and 10mm backward in order to have the front sprocket closer to the swing arm spindle. Attention, the kick axis is getting really close to the frame. |
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07/01/2006 For the upper rear mounting bracket, I think I'll use the stock FZR mounting on the left side of the frame. Tube length : 78mm plate thickness : 4mm For the right side, I don't know if I use the 10mm mounting ( big bolt) or the 2 6mm stock mountings (down - right image) . |
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08/01/2006 Here is the draft drawing of the lower engine brackets, I'll make the CAD modeling in order to make them on a CNC machine. ATTENTION new measurements |
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14/01/2006 CAD file views |
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15/01/2006 Left hand frame needs to be modified. The red will be removed |
  
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23/01/2006 New CAD file with a system that can directly do the CNC program |
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29/01/2006 Frame modification for the kick axle Some small modifications have to be done in order to give some clearance. |
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04/03/2006 Hel Brake line kit for FZR400RR from ebay UK at 45 euros |
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05/03/06 First mounting bracket for upper LH engine |
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05/03/06 Testing the FZR400RR fairing on the bike on the clutch side to check clearance. |
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31/03/2006 Before ordering the GRP fairing and selling the stock parts, a little test is needed. I think that a replica fairing could fit but one piece lower fairing will make me problems. |
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31/03/2006 But for the lower pipes it should be OK. |
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23/04/2006 Here are the upper pipes (plasma CNC cut with the help of my brother Laurent). I need to find now the right person to roll and weld them. |
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02/09/2006 First hand made left bracket by a colleague Jose Luis |
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10/09/2006 First test for the left hand bracket |
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18/12/2006 I've started to modify the FZR400RR Tank in order to have some space for the rear pipes. I'll cut all the under tank and make a new straight under plate. I'll need to weld it with the fuel sender and the petcock mounting plates. More details on the dedicated page 08/02/2009 |
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15/01/2007 I've been able to source carbon silencers for my project from a USA-Chinese company. I'm currently working with them to be a representative for French customers. Typical mounting patterns are TZR250 3XV & TZ250. Diameter is 6cm and length 25cm. More details, contact me. |
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30/01/2007 I've manage to be on ebay a steering damper fork bracket from Lockhart Phillips. |
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16/08/2007 I've been able to check the XJR1300 fork cap could suite to the FZR400RR front fork? I've done some measurements and I'm waiting for breaker confirmation on data ( www.fert-demolition.com very pro.). |
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25/08/2007 From left to right : Origin XJR set-up compare to FZR400 one / Shortened tube (115mm) / Complete set-up ready to mount. |
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25/08/2007 Now the FZR-RD has an adjustable spring in the front end. |
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26/08/2007 Lower engine cradle using shock bracket mounting on the crankcase. |
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02/09/2007 KR1 carb mounting tests |
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02/09/2007 Frame needs to be altered for upper carb |
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02/09/2007 View from the inside. |
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02/09/2007 Frame modification to be done |
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08/09/2007 Frame modifications and radiator mounting. I've put individual filter but it is better to build an airbox. I've some technical papers to read first. Any advices welcome. |
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09/09/2007 I've opened the FZR400RR airbox and I found that using the trumpets could be a good starting point for the design of the airbox. From what I've read the 2 strokes do not like long trumpet but short ones. This is a good point because the fairing will not fit with the FZR400RR trumpets on the KR1 carburettor. |
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23/09/2007 Fairing on for the airbox design |
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28/10/2007 Modification of the frame casting to get more space for the pipes. |
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28/10/2007 Testing with the pipes. |
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02/11/2007 Coolant Bottle in place |
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04/11/2007 Upper bracket almost done. |
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05/06/2007 Upper bracket done with stainless plate. Later on, will receive an anti-rust + phosphating treatment before painting. |
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06/11/2007 Lower bracket in stainless plate RH and LH |
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06/11/2007 The engine is mounted with the brackets. To be checked if the front mounting is necessary ? |
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11/11/2007 I've decided to build light front brackets even if they are not needed. They'll l help to hold some components like HT coils... |
   
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Page 3 15/10/2009 |
