RD500LC and FZR400RR project
Page 5
Updated : 26/05/2015
I've 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) |
Legend |
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18/01/2010 I finally manage to remove the fly wheel that was sticked on the crank (thanks Georgy). The TZR250 stator will be used in the RD500 engine. |
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23/01/2010 RD500 and TZR250 stators |
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23/01/2010 Comparison of stators on the left the 500 and on the right the 250. |
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23/01/2010 Comparison of pickup on the left the 500 and on the right the 250. The mounting plate of the 250 pickup will have to be turned over to fit. |
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24/01/2010 The 500 pickup is moulded so the 250 one need to be modified. |
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24/01/2010 On the left the 500's stator in his case and at the right the 250 one in the 500 case. |
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27/01/2010 Lower pipes on the bike with stainless brackets |
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28/01/2010 The main jets arrive in size 100/110/115/120 (I've had ordered 110 to 125 !!!). So 100 will not be useful !!! |
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06/02/2010 Stator case milling for TZR250 mounting points (José Luis) |
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07/02/2010 I've found from ebay a pair of FZR400RR Sport Production alloy clip-on. |
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07/02/2010 Alloy airbox fabrication (step 1) |
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09/02/2010 Carburettor to airbox junction (version 1). |
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10/02/2010. Test with the neoprene duct. |
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14/02/2010 Alloy airbox fabrication (step 2) |
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21/02/2010 Alloy airbox fabrication (step 3) |
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06/03/2010 Garage cleaning and a bit of sanding. |
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13/03/2010 Alloy clip-on blast sanded and anodised (310g each) on the bike. steel bar -> 620g (-310g) weight bar -> 310g |
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18/04/2010 Small bracket to maintain pipe spacing. |
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23/04/2010 Carburettor to airbox junction (version 2). |
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25/04/2010 Neopren pipe connected to carburettor junction and to alloy airbox. Airbox have been modified to deal with tube lenght (so need to be redone). Frame may be trimed too to give more clearance (red line). |
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15/05/2010 New pipe routing for more clearance and airbox modification. |
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29/06/2010 New fuel tap and repair kit for fuel sender |
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11/11/2010 Silicone cooling ducts |
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14/11/2010 Mokeup of a front engine bracket... |
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20/11/2010 Mokeup of a front engine bracket... Need to check with fairing. |
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21/11/2010 Not good with the fairing so I change the shape. |
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28/11/2010 It is getting cold in the garage ;-) 5°C Cut the fairing for lower pipe. |
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05/12/2010 Other side almost done. Small adjustments to be done. |
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11/12/2010 Clutch Case needs to be modify. Will have it cut and reweld to reduce the width. |
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12/12/2010 Fairing and stator cover. Seems to fit properly !!! |
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23/01/2011 New front bracket prototype. Close to the final solution. |
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23/01/2011 Seat support reinforced |
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01/02/2011 Repair kits for my keihin PWK28 |
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01/02/2011 CAD of the lower support |
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05/02/2011 Modified clutch case: cut, reweldded. |
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07/02/2011 Repair kits for my keihin (originaly made for Kawasaki KR150R) |
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08/02/2011 CAD of the lower support V2 |
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31/10/2011 CAO V3 : goal use the front mounting to make a close frame to the sterering head (ala TZR250). Wideness :
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06/11/2011 CAO V3 Bis Another approache with tubes. Little mockup and then CAD. |
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16/11/2011 CAD V5 |
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11/12/2011 Top rear bracket modification to fit with gearbox case modification. |
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28/01/2012 Small update => bad weather outside !!! Reset of the Tachometer : Test on the TZR125 then the FZR400 29/01/2012 Custer back on the bike. |
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15/04/2012 Airbox version 2 or 3 !!! |
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20/04/2012 Lower bracket update (small one) |
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22/04/2012 Folded version with PVC expanded plate. The shape and measurments seem OK to build the airbox in standard PVC sheet or alloy plate. |
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08/05/2012 Manage to find someone who can make the airbox in 3mm alloy sheet. The 4 lines and the lower fairing on. Some adjustments are needed. |
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14/05/2012 Modification of 2 lines position. fairing fitted Electronics on !!!! |
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20/05/2012 First layer on tank Tank Page for more detail |
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20/05/2012 Seat bracket and fairing bracket painting. Silver paint from Motip |
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20/05/2012 Pipe cleaning, unrustying and protecting (phosphoric acid). HT paint from Motip |
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20/05/2012 A little building up... |
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07/06/2012 CNC engine brackets but in PVC too check (Thanks Denis !) |
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07/06/2012 New multipart electrical boxes bracket... more easy to mount and dismount!!! |
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07/10/2012 I think I've got the final design for the under bracket. |
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17/03/2013 The XJR1300 fork caps went on the FZR400 fork which take place on my track day TZR250. |
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26/05/2013 Studying the design for upper mounting modification to fit a Yamaha model tuning rear shock : YZF750 Going from 12mm to 10mm ? |
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08/06/2013 Dismantling of the YZF750 shock...Un-rust and metal protection before painting. 12/06/2013 Nickel plated spring and stopper |
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17/06/2013 4mm steel engine bracket and laser cut. Thanks Georgy ;-) |
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19/10/2013 TZ250 seat modification to close the gap with rider seat pad. |
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19/10/2013 TZ250 seat modification cutting the lower part to make it more fluid. |
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19/10/2013 TZ250 seat modification helps to mount it easily without hurting the upper pipes. |
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26/05/2015 |