Finally reached the start line.

Its been a long time and many a late hour has been spent in the damp garage but today we finally generated smoke and noise from the RGV. I'm talking about the 250 not the 500.
Before I get to the 500 I'm going to indulge myself with a paragraph(s) and picture(s) about the VJ21.

When the 500 project turned up I chose to leave it alone until the 250 was complete. Inevitably this meant the 250 project took a different direction to what I set out to do and it has not reached the perfect Pepsi that I had in mind. What I mean is I took some shortcuts to get it out of the way.

Engine - Its a long story but It is wearing 250 L barrels (these take the 22DO pistons) - the porting is much larger than the K cylinders. The porting is still conservative compared to VJ22 but I wanted a standard type of engine and didn't want to start messing with the 2 stage powervalves on the '22. I had a set of 22 barrels and swapped them with Col (he will be mentioned again later) for the 250 L's.
I've lifted the barrels by 0.50mm over standard and machined the heads to step the combustion chamber into the barrels. Its running 0.80mm squish and the combustion area has been profiled to give just over 13:1 UCCR so I'm close to the limit of what I can get away with from the Shell forecourt. I'll see how hot it gets and might end up chucking a splash of Ethanol in the fuel to cool it but we'll see. Other than that the engine is bog standard so it should run pretty good but the exhausts are likely to spoil things over 10k rpm but at least they might save the engine from being revved to death. I bet I end up with some fruity pipes after my first track day.
I worried that lifting the barrels would make it struggle at low revs but it pulls smooth and strong from tick over - I'm amazed - It's easily as smooth and progressive as my old 350 YPVS.

Anyway it ended up in non standard clothes but it does look pretty smart, just the smoked screen lets it down (I hate smoked screens) A replacement clear screen is on its way from Skidmarx via Crooks Suzuki and should be fitted at the weekend along with a fresh water pump. It will get an MOT, Tax then have a few shake down runs along the Coast Road then its off to some track days wearing some of the tons of spare bodywork I've got.

Remember that shell suit that you loved... My RGV is wearing it.

Looks pretty smart I think and I managed to get some Dunlop track sticky rubber for that 18 inch rear. Its all new, freshly painted and polished and feels nice and tight. the forks are GSXR400 because they have better damping but with standard springs (see Vincent Crabtree blog) and Goodridge front lines. what more dy'a want?

I have to say TA to Alan in Carlisle for the chat and bodywork. when building project bikes you meet loads of people who share a liking of garage tinkering, Ive met loads and it makes me laugh. I thought I had it bad but when I met Alan to do a deal for the body work I found he had 3 RGV's and a pair of GSXR250's all getting the treatment . I've got to hand it to you Al, you're mad for it and you will have a sweet collection in the end.

And here it is in its natural environment. I will get it a bag like what the GSXR has been in all winter. Side note - the GSXR has remained perfectly stored all winter and the alloy is gleaming as much now as the day I packed it. What a marvellous invention - a huge plastic bag.

lost in a world of rubbish. Note the Santa-Fe Express next to the GSXR, its a beast!

Now lets get back to business. The 500

Although I've restrained myself I have been doing some homework and bought an engine cradle from Mark at Performance Fabrications. It wasn't cheap at £230 but the quality is excellent so its a fair price for decent work. Ta.
I got a GSXR 750 rear wheel to match the front and it fits in the swing arm wearing a 180 even with the spindle forward in the slots. Chain line is going to be a challenge and I suspect the sprocket carrier is going to need some creative machining but I'll figure that out later. I'm pleased as I'll be able to get plenty of choice when it comes to putting tyres on.

Air filters. I suspect this is going to be the area that 500 owners ponder for eternity. the project came with some of those expensive filters from RG500.com however I might not bother with them.
I'm only guessing but I can imagine these motors dyno better than they actually achieve on the road because air must rush past the filters and almost pull air back out of the carbs at speed. I just cant see how  air is going to turn through 90 degrees in the area of a carb inlet when its moving at over 100 mph. With this in mind I'm favouring air boxes with good sized inlets in the fairing. Again I'm sure this is a well trodden path i'm on
I bought 2 sets of carbon airboxes from Germany so I can use these as a start point when i get to that point in the project.

Frame. No progress although I have had half an eye open for a decent after market shock. I would like something I can change the spring easily as I suspect I will need to change the spring rate to compensate for the heavier motor. maybe?

Bodywork. I fancied Tyga but I've gone off it. It is too obvious and been done to death. On top of that I think the back end is too big and the more I look at the overall shape I feel it looks like something from the mind of an American airplane designer of the 80's. It looks like a Boeing.
I want the back end to be short and the new Mito Evo is pretty cool but It might age quickly?? I like the look of it and I also like the look of the new Ducati Streetfighter, that would give a cool rear and the pipes would look great with it.
As for the fairing there is only one bike in the world I think is truly perfect and will age as well as the Ducati 916 design did. The Ducati Desmosedicci is the ultimate bike design and not just the bodywork. I spent some time with one and it really is as near perfect as you can imagine a bike can get. Worth every penny if you can afford it.
I'm tempted to try and get a Desmo fairing on my RGV but it will need some heavy modification as the Ducati blends into the tank and back end with unbroken lines between the panels. The back end has the exhausts exit out of the top where a pillion would be sat. I'm not sure about that bit but Ducati have made a beautiful job on the Desmo.
I need to decide before I write my project spec.

Engine. I'll go here in the next instalment

...and in the beginning. Day 1 of the rest of my life

Side note on my bench.
My dad made that bench when I was a kid - he was a joiner and used it to cut wood etc.
It has seen many bikes of mine..AP50(proper old one) AR50(s) DT50 RG250 YammaGamma YPVS(s) 350LC GSXR(s) WR400 KDX200 RGV250 etc, even a woman once. I cant remember them all but needless to say that the 500 will be worshiped at this Oily Alter. You can keep your bike lift!