Project light weight

[gixerboy]

I have a few RGvs in various states of disrepair, this M model Vj22 I bought for £650 18 months ago, it needed as new rear tyre and then went straight through the MOT. I rode it for a few thousand miles and then it blew a head gasket. While I was replacing the head I thought I would treat it to a new top end. I also modified the power valves as one of the pins was loose.

https://img.photobucket.com/albums/v106/gixerboy1/rgv.jpg

https://img.photobucket.com/albums/v106/gixerboy1/right.jpg


Now I am ready to put the engine back, in I decided to start on a project to make the bike lighter and a little more modern looking while keeping the rgv shape. The earlier RGV weighs 8kg less as standard, while this model has steel subframes, so I thought I would put it on a diet and see just how much weight could be lost.
First thing was to replace the heavy, steel headlight bracket with an aluminium one I had made by a local fabrication shop (400g saving).

https://img.photobucket.com/albums/v106/gixerboy1/IMG_4121.jpg

I also fitted a set of aluminium chain adjusters that I made (200g saving)

https://img.photobucket.com/albums/v106/gixerboy1/chainadjusters.jpg

I decided to use a set of Aprilia RS250 wheels(not weighed them yet) and a set of Marzocchi forks (2kg saving) I had on one of my other rgvs. I made the yokes to hold the forks (a weight saving of 1.8kg) and turned the wheel spacers.

https://img.photobucket.com/albums/v106/gixerboy1/rswheels.jpg

I also fitted a set of clip ons I made (580g saving) and a radial master cylinder I got from ebay cheaply.

https://img.photobucket.com/albums/v106/gixerboy1/master.jpg

https://img.photobucket.com/albums/v106/gixerboy1/anoclips.jpg

I have a few other things on the go at the moment and will post them as they go on the bike.

[Gazdaman]

I don't think you're the every day 'bodge something up in the shed with some old plumbing stuff and cables ties' kinda guy are you?

I turn up wheel spacers and get stuff fabricated all the time...

Absolutely stunning bike, I'd love an RGV250 as a track bike.

Gaz

[Deano]

if you wanna save a lot more get some light weight wheels, chop the subframe or get alloy 1, adn get rid of alot of the road going gear.

[Whosthedaddy]

Its a stunning bike to start with
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Current : MSX 125 Past : CBR 900RR Monkeybike : c50 LAC : ZXR750 H2 : FZR600 : ZX7R P3 : YW100 : TRX850: Trophy 900 T309 : GSXR 600 L0: Monkeybike : XJ6S Whosthedaddy

[gixerboy]

[quacker_boy]

You MADE those chain adjusters and clip ons?! F**k me they're pretty pukka!

Got a close up of the yokes as well?

I'm assuming you work in a metal working shop of some kind

I like the look of those forks and new callipers and discs on the front as well
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wizzzard wrote: Imagine God just stopping by, tidying your front room up and then quietly letting himself out again. Statisticly more likely to happen than Korn being on here.

[gixerboy]

[Gazdaman]

Those are seriously beautifull...

I hope they work as well as the look.

Gaz

[lilredmachine]

Just make sure you don't eat too much before you get on it, or you'll make all your weight back up

That is a seriously sexy bike, and, damn, boy got skillz.
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Bikes: too many, too much for one man to maintain anyway.

[quacker_boy]

Christ mate, i might have to commission you to make some custom parts for me when i get my next bike

Do you take orders?
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wizzzard wrote: Imagine God just stopping by, tidying your front room up and then quietly letting himself out again. Statisticly more likely to happen than Korn being on here.

[gixerboy]

I used to do a bit of batch work, but I tend to just design the stuff that I sell and send it out to be made, I only make parts for my own bike now.

These are some of the things I made to sell.
https://img.photobucket.com/albums/v106/gixerboy1/yokes1.jpg

https://img.photobucket.com/albums/v106/gixerboy1/d083aec4.jpg

[quacker_boy]

I can see that being a real money maker, but also very time consuming!
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wizzzard wrote: Imagine God just stopping by, tidying your front room up and then quietly letting himself out again. Statisticly more likely to happen than Korn being on here.

[Whosthedaddy]

Loving everything so far except the vile adonized stuff, cool bike and a nice little project.

So, just out of interest, how much for some of the dodads?
____________________
Current : MSX 125 Past : CBR 900RR Monkeybike : c50 LAC : ZXR750 H2 : FZR600 : ZX7R P3 : YW100 : TRX850: Trophy 900 T309 : GSXR 600 L0: Monkeybike : XJ6S Whosthedaddy

[Spoonman]

lookin' wicked!!

[Jack_Cheese]

You saved 1.8 kg on the yokes alone!? what were the OE ones made from? lead?

Nice bike, I'm considering an RGV for a first post-test bike, but i've heard the motors aren't the most reliable of 2-strokes, and the powervalves are an absolute bitch to get hold of when one breaks or wears down.

Looks like an absolute scream of a bike though How on earth did you get it for £650!?

jack
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www.bikepics.com/members/jackcheese <--- NOW FOR SALE! 51 Plate Cagiva Planet 125
Quacker_boy: "Jack, you really are a dick!"

[gixerboy]

The standard yokes are made of steel, along with all the subframes, that is one of my pet hates on the Vj22 rgv250.
The powervalves are not difficult to get hold of, you can pick a complete set up for less than £100 if you know where to look. The RGV is in quite a high state of tune but if you look after it, it will not cause you too many problems, there are a lot of horror stories of all high performance 2 strokes, but most of the problems are caused by hamfisted owners.
I picked this one up off a local rideout forum that I belong to, the forum owner saw I had a couple of RGvs already and put me on to this one that a forum member was trying to sell. He wanted a bit more but I bargained with him. It came with some spares which I sold for £200 as well, so all in all it wasnt a bad buy.

[phatstorage]

you could always take a big shit before you go out on it

200g saved

[Whosthedaddy]

[winwick]

it aint about overall wieght you dumbass.
look at where the wieght is being shaved from and then think about how it'll effect the bike.
jesus some people are so fookin stupid

[gixerboy]

It could be worse, I could own a KR1 and start putting heavy RGV parts on it.

[gixerboy]

Not much progress recently, mainly waiting for a few parts to be finished before I can make the brackets and other parts to secure them. Body work is in the middle of being modified before I can take a mould from it to make them in either carbon fibre or fibre glass, depending on what I can find lying around at work.
I have finished modding the mito stand and that will be fitted at the weekend:

https://img.photobucket.com/albums/v106/gixerboy1/sidestand.jpg

The stand on the left is the standard RGV one, the one in the middle is the mito stand I have modified and the one on the right is a standard mito one. The Modified one weighs less than half the standard RGV stand.

I have had a bit more welding done to the aluminium subframe. A few more brackets have been put on and some of the mounting points for the bodywork. The battery box has also been put on. The engine has been rebuilt and is ready to go back in the bike now.

https://img.photobucket.com/albums/v106/gixerboy1/subframe5.jpg

[Deano]

jinx.
i fitted the mito sidestand to mine and i get a 1kg weight loss.

[Andy C]

man that is cool

I hope you get it completed just in time for spring

You changing the body work?? I think you should keep current as very nice!! Nice DEP exhausts, is that full system?
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99 RS125 --> 02 SV650s --> 03 Speed Four --> 92 RXS100 --> 93 CB400sf --> 01 CB600f Hornet

[Biker100]

very nice work so far, keep us updated

[JBurrows88]

I Like very cool


When you finish you will have to tell us what the overal weight is and how much you lost off the original!
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Dave
XJR400 Kenney Roberts Paint Job