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Classic Bike Trackdays

RG250 mk3 Walter Wolf re-creation - resto
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Straycat



Joined: 22 Jul 2015
Posts: 165
Location: Canada

PostPosted: Sun Apr 03, 2016 6:55 pm    Post subject: Reply with quote

Good day in the work-shop today. The Gamma Lives! I fired it briefly on a spray of fuel.

Today, I cleaned and rebuilt the carbs, installed the carbs and hooked up the oil pump/cable, tested and installed the Power Valve Servo, Rigged the power valves, installed the new bar grips, painted the bar end weight caps, installed the battery.

Next week, I hope to install the new Chain, connect the fuel lines, reinstall the left side engine cover, connect the front turn signals. If i feel energetic, i may swap the white face clocks for the Walter Wolf set i got, and see how easy/hard it is to figure out how to connect the fuel gauge (Canadian Bikes had no fuel gauge , and no sender in the tank, but my new tank and WW clocks do....just the wiring harness to figure out...its different on Cad bikes)

and now that i see it in a picture , that PV servo bracket looks like SH12 so i may have to swap that out.




_________________
2014 Honda VFR800
2015 Yamaha FJ09
2000 Kawasaki ZRX1100
1989 Yamaha RZ350 ypvs
1989 Yamaha FZR400
1987 Suzuki RG250 Gamma
1986 Honda NS400R
1988 RGV250 VJ21A-J
1986 Honda TLR200 Reflex
1985 Honda VF1000R (x2)
1985 Yamaha RZ500


Last edited by Straycat on Sun Apr 03, 2016 8:39 pm; edited 1 time in total
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The Cameraman



Joined: 22 Aug 2015
Posts: 608
Location: Lancashire

PostPosted: Sun Apr 03, 2016 7:39 pm    Post subject: Reply with quote

Hi Straycat,

a very productive day.
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Kindest regards


Reggie
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Straycat



Joined: 22 Jul 2015
Posts: 165
Location: Canada

PostPosted: Sat Apr 16, 2016 6:58 pm    Post subject: Reply with quote

Chain is on, Pipes on, clutch done, started to fit some body-work so i can layout the decals, still have to mount the lower belly fairing.

I also need some bullet connectors, need to re-connect the front signal lights (Winkers), the female bullets-connectors were cut off the bike, so I need to re-do that.

Add oil, add coolant, finish making my remote fuel supply feeder bottle and i can start running & tuning.

I have a set of Digitron EGT's (Exhaust Gas Temperature Sensors) that I may fit, makes tuning and jetting easier, and also gives you ample warning if your ever on the verge of burn-down due to a lean condition. The main unit is transferable bike to bike or sled to sled, just need a set of sensors and a power cable for each bike you want to use it on









_________________
2014 Honda VFR800
2015 Yamaha FJ09
2000 Kawasaki ZRX1100
1989 Yamaha RZ350 ypvs
1989 Yamaha FZR400
1987 Suzuki RG250 Gamma
1986 Honda NS400R
1988 RGV250 VJ21A-J
1986 Honda TLR200 Reflex
1985 Honda VF1000R (x2)
1985 Yamaha RZ500
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Straycat



Joined: 22 Jul 2015
Posts: 165
Location: Canada

PostPosted: Sat Apr 23, 2016 8:32 pm    Post subject: Reply with quote

Well im really pissed off today, i put coolant in it for the first time and i have leaking head gasket. its weeping coolant externally left cylinder, either between the 2 cylinders Front right corner of the left cylinder, or its leaking around the power valve from the left cyl - hard to tell. I used OEM gaskets for the head and base.

Checked the torque on the bolts - max 27nm for the 8mm nuts and 11nm for 6mm bolts, all ok, Damn I hope i dont have to pull the whole bike all apart again.

now im second guessing if i put the gasket n the upside down

I may try and run it tomorrow see if a heat cycle stops it, other wise ill have to see if i can get the head off with the engine still in place, and get another new Suzuki gasket.

I didnt get the head milled but i checked it for being straight and flat

feel like chucking a match on it
_________________
2014 Honda VFR800
2015 Yamaha FJ09
2000 Kawasaki ZRX1100
1989 Yamaha RZ350 ypvs
1989 Yamaha FZR400
1987 Suzuki RG250 Gamma
1986 Honda NS400R
1988 RGV250 VJ21A-J
1986 Honda TLR200 Reflex
1985 Honda VF1000R (x2)
1985 Yamaha RZ500


Last edited by Straycat on Sat Apr 23, 2016 11:34 pm; edited 2 times in total
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Straycat



Joined: 22 Jul 2015
Posts: 165
Location: Canada

PostPosted: Sat Apr 23, 2016 10:50 pm    Post subject: Reply with quote

The good news I ran the bike on a fuel supply for the first time, and the bike runs well, 3 kicks and it ran like a top, I really needed that.

More bad news in that one of the carbs is leaking fuel, not sure if its the crossover pipe between the 2 or the bowl gasket on the right side carb. Those of you with Gamma's will know the pain and suffering that will follow when taking carbs back of this bike, simply awful getting them off.

I pulled the left side power valve out too, no sign of coolant in there, so its the head leaking externally only

may see if the head will come off with the engine in place, really don't feel like pulling the motor again.
_________________
2014 Honda VFR800
2015 Yamaha FJ09
2000 Kawasaki ZRX1100
1989 Yamaha RZ350 ypvs
1989 Yamaha FZR400
1987 Suzuki RG250 Gamma
1986 Honda NS400R
1988 RGV250 VJ21A-J
1986 Honda TLR200 Reflex
1985 Honda VF1000R (x2)
1985 Yamaha RZ500
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The Cameraman



Joined: 22 Aug 2015
Posts: 608
Location: Lancashire

PostPosted: Sun Apr 24, 2016 5:19 am    Post subject: Reply with quote

Hey Straycat,

finger are crossed for you mate.
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Reggie
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Straycat



Joined: 22 Jul 2015
Posts: 165
Location: Canada

PostPosted: Sun Apr 24, 2016 12:26 pm    Post subject: Reply with quote

Thanks Reggie, appreciate that.

I did nip up the head bolts after I ran the bike a bit yesterday. 2 needed to be re torqued

after leaving it over night, the paper towel i stuffed in between the cylinders where the leak was had only one tiny wet spot on it, the same amount that i was getting every 5 minutes before.

I may have solved that, but we will see in another day I guess, best not count my chickens just yet.

The carbs will have to come off, Ill get some OEM bowl gaskets for those, the pattern /aftermarket ones may not be good enough, ill be at the suzuki dealer tmo
_________________
2014 Honda VFR800
2015 Yamaha FJ09
2000 Kawasaki ZRX1100
1989 Yamaha RZ350 ypvs
1989 Yamaha FZR400
1987 Suzuki RG250 Gamma
1986 Honda NS400R
1988 RGV250 VJ21A-J
1986 Honda TLR200 Reflex
1985 Honda VF1000R (x2)
1985 Yamaha RZ500
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Straycat



Joined: 22 Jul 2015
Posts: 165
Location: Canada

PostPosted: Mon May 02, 2016 4:18 pm    Post subject: Reply with quote

Carbs sorted, Coolant leak seems to have been solved (fingers are still crossed).

Swapped out the nasty corroded Power Valve bracket for a nice one.

Lower fairing on, just the decals to put on and then get the tank re clear coated.

Still have to wire up the front turn signals too.

I've run it a few more times, runs nice, Have not get put it in gear to ride it though...soon.

Who ever invented the fairing fastener system on this bike is not my favourite person.






_________________
2014 Honda VFR800
2015 Yamaha FJ09
2000 Kawasaki ZRX1100
1989 Yamaha RZ350 ypvs
1989 Yamaha FZR400
1987 Suzuki RG250 Gamma
1986 Honda NS400R
1988 RGV250 VJ21A-J
1986 Honda TLR200 Reflex
1985 Honda VF1000R (x2)
1985 Yamaha RZ500


Last edited by Straycat on Mon May 02, 2016 4:37 pm; edited 2 times in total
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The Cameraman



Joined: 22 Aug 2015
Posts: 608
Location: Lancashire

PostPosted: Mon May 02, 2016 4:24 pm    Post subject: Reply with quote

Hi Straycat,

she's looking well fine.
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Kindest regards


Reggie
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Straycat



Joined: 22 Jul 2015
Posts: 165
Location: Canada

PostPosted: Mon May 02, 2016 4:38 pm    Post subject: Reply with quote

thanks Reggie
_________________
2014 Honda VFR800
2015 Yamaha FJ09
2000 Kawasaki ZRX1100
1989 Yamaha RZ350 ypvs
1989 Yamaha FZR400
1987 Suzuki RG250 Gamma
1986 Honda NS400R
1988 RGV250 VJ21A-J
1986 Honda TLR200 Reflex
1985 Honda VF1000R (x2)
1985 Yamaha RZ500
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Straycat



Joined: 22 Jul 2015
Posts: 165
Location: Canada

PostPosted: Fri May 06, 2016 1:35 am    Post subject: Reply with quote

Here are the decals.

Blue tape to mark where the stripes will go
White tape to be the guide once the blue comes off
Tank wet sanded before decals went on, just needs clear coat now

best to do it this way with stripes , if you don't its too easy for the stripes to be running on different angles and it ends up looking like the bike is bent
















_________________
2014 Honda VFR800
2015 Yamaha FJ09
2000 Kawasaki ZRX1100
1989 Yamaha RZ350 ypvs
1989 Yamaha FZR400
1987 Suzuki RG250 Gamma
1986 Honda NS400R
1988 RGV250 VJ21A-J
1986 Honda TLR200 Reflex
1985 Honda VF1000R (x2)
1985 Yamaha RZ500


Last edited by Straycat on Fri Oct 21, 2016 8:47 pm; edited 1 time in total
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steezin_and_wheezin



Joined: 07 Jul 2015
Posts: 68
Location: Radford, VA(USA)

PostPosted: Fri May 06, 2016 3:06 am    Post subject: Reply with quote

Top notch work! Fantastic job, you've done the old Gamma right!!
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The Cameraman



Joined: 22 Aug 2015
Posts: 608
Location: Lancashire

PostPosted: Fri May 06, 2016 3:45 am    Post subject: Reply with quote

Spot on!
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Reggie
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Top-shaggy
Show Star !
Show Star !


Joined: 05 Mar 2011
Posts: 1678
Location: Derbyshire

PostPosted: Fri May 06, 2016 6:24 am    Post subject: Reply with quote

Looks fantastic ..great job Smile
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Straycat



Joined: 22 Jul 2015
Posts: 165
Location: Canada

PostPosted: Fri May 06, 2016 11:26 am    Post subject: Reply with quote

Thanks fellas, its amazing how much difference the decals make. the dark blue paint looks a bit drab on the bike till you put the decals on.

Ill take the tank in tomorrow for clear coat

I found that some of these decals were a bit of a problem. I suspect the top side transfer/release tape ( the semi transparent sticky layer on top of the decals, that you can squeegee over, and then peel off to aid in application) must have been applied too soon after the decals were printed.

on a couple of the the red "W" stickers the gold ink bonded with the glue on the release layer and left some marks on the stickers. it happened on the stripes too, but thankfully they were long enough I could position them so that the defective part was cut off and scrapped.
_________________
2014 Honda VFR800
2015 Yamaha FJ09
2000 Kawasaki ZRX1100
1989 Yamaha RZ350 ypvs
1989 Yamaha FZR400
1987 Suzuki RG250 Gamma
1986 Honda NS400R
1988 RGV250 VJ21A-J
1986 Honda TLR200 Reflex
1985 Honda VF1000R (x2)
1985 Yamaha RZ500
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