1994 RVF400R Build Project

Discussion in 'Mechanics Garage' started by NorcalBoy, Nov 7, 2018.

  1. NorcalBoy

    NorcalBoy Member

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    This is the first installment of me documenting my latest build project.

    Today, I had to come up with a radiator screen/protector for the new carbon inner cowl. I used R&G Racing titanium expanded metal mesh/screen as the material of choice. The fact that it is blued made it that much better for the overall scheme.

    First, I had to come up with a template, didn't wanna waste the material, due to replacement cost, lol.

    [​IMG]

    The mounting bosses formed into the piece are not symmetrical, of course. All carbon requires a certain level of "massaging" to get it to fit perfectly.

    Next I used some left side and right side snips to cut out the basic shape

    [​IMG]

    I carefully cut in some locations for isolation grommets, didn't wanna just screw it to the cowl direct, inelegant at best, lol. Used ti and aluminum fasteners from ProBolt to check the attachment.

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    Once the mounting was confirmed, I temporarily wrapped the outside edge of the ti mesh with 1/8" vacuum hose, split longitudinally. I wanted a "finished" look, even if it was hidden inside the cowl.

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    This is what it ended up like for the first go round. It will prolly need to be trimmed to fit the actual opening where the side cowls and inner cowl all join , but I don't have the machine here to check it, so I left it long

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    Once I know exactly how much clearance it requires on the bottom, I will trim it up and permanently install the piping trim. I think it's going to work good to keep the schmutz off of the new race radiators I ordered from Rick Oliver in the UK. 40% better cooling capacity than standard rads, hand fabricated by British virgins somewhere very top secret in the UK. For what they are asking for those, they HAD to be protected, plus I didn't want debris hitting my race header.....I will post up the final final, once it's all trimmed up and permanently mounted.

    R&G Racing UK
    ProBolt USA
    Rick Oliver NC30/NC35 UK
     
    Last edited: Nov 7, 2018
  2. NorcalBoy

    NorcalBoy Member

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    Today I received the last of the bits I needed to accomplish the complete overhaul of the stock brake system.

    Today, I received the titanium ti nitride coated rear caliper pistons that I needed. Also got the ti chainguard and valve cover bolts, the titanium swingarm pivot nut and the ti sim washer for the rear axle.

    [​IMG]

    I already received all of the other ti bits and piston seals to refurbish the front and rear calipers, posted this pic in the other thread, but I'll put it in here too.

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    I went with EBC Vee Rotors because they are 28% lighter than the old X-Discs. EBC EPFA pads for the front calipers, GoldFren FA pads for the rear caliper with an EBC Pro-Lite rear rotor. Have a DLC coated ti rotor mount bolt kit from ProBolt to handle the attachment to the newly powdercoated wheels, in black.

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    I went with HEL braided lines for the front and rear, I also have two different solutions for the front lines and I'll decide which ones i'll use when the time comes. I went with a Brembo RCS17 radial for the master cylinder with the smoke reservoir kit, a TWM clutch lever and perch from UK Racing Services, and a Domino quick turn throttle assembly. The banjo bolts are ProBolt DLC coated, front and rear all.

    [​IMG]

    I plan on using Nils at Restocycle to vapor blast the caliper bodies. That will determine whether or not the calipers need to be coated, if so, Cerakote high temp ceramic coating will be used.

    Today I ordered a Hyperpro, 140mm, side mount damper with a reverse damper mounting kit to keep the rod away from the rider and bodywork, a complete ground upgrade kit and NGK HT leads for the coils. Discussing the ignition system with Rick, trying to decide on coils, RR and stator, and, most likely, a programmable Ignitech TCI unit to handle the ignition. Discussing which maps I want loaded on the unit by Rick.

    Already learning a few things about these machines, can't wait to play around with it and get to wrenching.

    Titan Classics UK
    KurveyGirl USA
    Treatland.TV USA
    HEL UK
    ProBolt USA
    UK Race Support Services
    EBC USA
    Kencourt Limited UK
    Rick Oliver NC30/NC35 UK
     
    Last edited: Nov 9, 2018
  3. OOTV

    OOTV Member

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    I'm liking those EBC Vee Rotors, I had been eying them for my 5 Gen but then had other things take priority. Still on my list of "next" thing to buy...
     
  4. Diving Pete

    Diving Pete Insider

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    I have the HEL brake lines on one of mine - 2 line from the master cylinder. I do need new lines for the white one as they are the original
    Using standard discs with HH pads
     
  5. NorcalBoy

    NorcalBoy Member

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    Nothing major to report, but I did get around to finalizing the ti radiator protection screen for the inner cowl.

    [​IMG]
     
  6. NorcalBoy

    NorcalBoy Member

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    [​IMG]

    Nothing major to report, just documenting the process. Received some more ti hardware from ProBolt. DLC coated windscreen mounting kit in black, gold anodized ti for the magnetic oil drain plug, Race spec ti bolts and washers for the airbox lid, countersunk screws for the new chain repro sliders. Have quite a few bits on the way and I'll continue to populate the thread as they come in.

    ProBolt USA
    Tyga Performance
     
  7. NorcalBoy

    NorcalBoy Member

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    OK just another update, only because I want to shill for some new folks working in my corner, yep, shameless plug.

    [​IMG]

    After the experience I had with my latest run with OEM Ohlins kit, I thought it was time for a big change. Not just the suspension provider, everything. I had heard some very good things about Fast Bike Industries, so I sent them an email. Literally, within minutes, David Behrend, the owner of Fast Bike called me on the phone. My first impression was pretty freaking good at that point. I went over my trials and tribulations with Ohlins and we had a very long discussion about what bikes I had ridden, what companies I had used previously, and what the end results had been.

    I actually surprised myself going through who I had worked with before, Race Tech, Pro Circuit, Mike Bautista at MB1 Motorsports, Traxxion Dynamics, and Ohlins USA. David listened to what I was looking for in suspension action, what type of riding I really did and what my true weight really was. He was very interested in my project. I told him I wanted to try Nitron Shocks from the UK, and Fast Bike has just taken over as their US supplier...good fit. I settled on the NTR3, 3 way adjustable custom race spec shock with the titanium colored spring. He sent me an invoice and I paid it.

    Exactly to the day he promised he would have the shock from Nitron, he called to say it was going out. The service seemed almost unreal at this point. We talked for quite awhile about machine builds and stuff, he never tried to brush me off. All I can say is great guy...I thought I might have stumbled onto something positive with David. The shock arrived a couple days later and it sure looked the business. Needless to say, I was pretty damn stoked.

    I had planned to use Traxxion AK-20 cartridges, just because I'm familiar with setting them up. Now I was rethinking it. So, I called up David and asked him what he could do for me. He told me he could build me a set of custom Andreani cartridges for quite a bit less cash and guaranteed that he could get them installed and set up to the exact specs I was looking for, I didn't think twice, told him he was going to do mine, but that I had a few bits to add and a few extra things I wanted done, no problem. David gave me the sale price of $584 for just the base cartridges and that the other stuff was no problem. Boom, Done!

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    These are the new DLC coated fork stanchions from Brook Suspension in the UK. These will be installed during the cartridge install and I'm also having some hardcoat anodizing done to a few bits as well. David is going to handle everything. Basically, I'm having Fast Bike custom build a set of superbike spec forks, that aren't Ohlins. Going my own way this time. I will have nobody to blame but myself this time, if shit goes sideways. I prefer it that way. All I can say is that I'm stoked to have started developing a relationship with David and his main man Burch, I really believe this change is going to bear some excellent fruit.

    BTW, I told him about cartridge options for VFR800's and he said he can build custom cartridges and get them installed in VFR forks with stock cartridges
    no problem at all, so if you 800 riders are looking for an option besides Jamie or Traxxion, David can take care of you. Just google Fast Bike Industries and give David a call, I'm sure you will be happy you did.

    Fast Bike Industries
    Andreani USA
    Nitron UK
    Brook Suspension UK
     
    Last edited: Nov 14, 2018
  8. NorcalBoy

    NorcalBoy Member

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    More parts arrived from RRP in the UK.

    [​IMG]

    Honda OEM mirror dampers, LiteTec carb to airbox gaskets, stainless captive front wheel spacers, and 6 each of the side infill trim clips, that way I will have extras on hand, just in case.

    The blue anodized device is a slick little item from Motrax that converts the speedo in kmh to mph....as there is no speedo dial available in mph and I don't want to be guessing or attempting to calculate my actual speed on the trot, this thing is a no brainer. With this installed, 40 kmh indicated on the stock speedo dial will now be 40 mph etc, etc. Keep it simple, stupid.

    I also received a full swingarm pivot bearing kit and seals, all Japanese components, just for Squirrelman :D

    The last two bits are a stator cover gasket and stator puller, not too hard to figure out where that is headed, sourcing a stator and Mosfet rr kit from Rick Oliver in the UK. It is a 24 year old machine, so I don't want any funny business going on, just going to go ahead and replace the components during the build. I am considering Rick's kit that allows the use of the GSXR 1000 lightweight rotor, the kit is complete, including a new stator cover required for the clearance of the rotor. Still undecided, but the prospect of a quicker revving engine does appeal to me on a technical level.

    This morning I purchased a Hyperpro side mount steering damper and the very trick reverse damper mount kit from Rick Oliver. This will allow the damper to be mounted so that the damper rod extends inside the upper cowl, instead of anywhere near the riders knee. This will also keep it more protected. I also purchased Rick's ground upgrade kit which allows the individual grounding of the wiring harness, both coils and the starter motor. This will eliminate any possibility of a dreaded Honda ground issue. Also on the way is a new set of NGK HT leads for the coils, which I haven't decided on yet. Rick is advising me on what coils I should use and I'm seriously considering a new ECU, with Rick's programming, which eliminates the known midrange flat spot associated with the stock ECU programming and the upgraded ECU will also allow the fitting of a quickshifter and a shift light, if I so choose.
     
  9. Diving Pete

    Diving Pete Insider

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    I think another choice is the cbr600 coil on sticks.. may be worth thinking about.
     
  10. NorcalBoy

    NorcalBoy Member

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    Just adding a shot of some more DLC coated ti hardware I received from ProBolt yesterday, why?, because I love me some DLC coated ti. Don't think I have a better reason, lol. Some people like pickles on peanut butter, fair 'nough, but I'll take ti, and hold the PB and pickles.

    [​IMG]

    This shipment closes the loop on the forks, bars, triples, rotors, and calipers. The axle spacers and axle are stainless, no such animals exist, unless I had my guy machine them from bar stock, I still may, but that won't be anytime soon, other fish to fry first.

    Placed the order from Rick Oliver for the Ignitech programmable ignition module, with Rick's +2 mapping, Ignitech coils and a MOSFET RR kit. I'm going to have these folks rewind my stock stator: http://racetechelectric.com/p-10524-rewinds-rd.html I already have a new starter relay, NGK HT leads for the coils on the way from Rick, the ground upgrade kit, an Anti-Gravity lithium ion battery sitting on the NOCO charger, and new battery cables...that should kill off what I need for electrical stuff. Full restoration of the ignition and charging circuits.

    Down to just a few more minor items to source, and the bike is supposedly going to be ready for shipment very soon. Can't wait to ride it, it's been a long wait! Happy Thanksgiving.

    Rick Oliver NC30/35 UK
    ProBolt USA
    Racetech Electric
     
  11. scottbott

    scottbott Insider

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    this looks interesting, must have cost a few bob so far, cannot wait to see the finished bike
     
  12. NorcalBoy

    NorcalBoy Member

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    You and me both. No matter how many times I do this, it never seems to get any quicker. The more you do, the more ideas you have. You have to up the game every time, the progression must always be to learn and push your skills and visions to the next attainable level. Never was very good at traditional art forms.
     
    Last edited: Nov 21, 2018
  13. Diving Pete

    Diving Pete Insider

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    I forgot to ask, will you be tracking this bike or for road use only ?
     
  14. Diving Pete

    Diving Pete Insider

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  15. NorcalBoy

    NorcalBoy Member

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    That never enters into my thought process, so I can't really tell you what it's future holds. It's more about the personal satisfaction of creating something that I feel I put everything I had into making it the best I could. I am very into the technical side of racing and the effort that gets put into a machine to make it the best weapon on the grid. The devil is always in the details.
     
  16. NorcalBoy

    NorcalBoy Member

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    Last edited: Nov 21, 2018
  17. Diving Pete

    Diving Pete Insider

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    Does that mean we get a li battery thread then.....
     
  18. NorcalBoy

    NorcalBoy Member

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    Not from me, however, I have been hanging around here for the better part of a decade and those types of threads seem to draw the most responses. Take that recent RR thread for example, should have been done in one post and it's prolly still droning on. :Deadhorse:
     
  19. NorcalBoy

    NorcalBoy Member

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    Tim from Moto2 Imports called today to give me an update, it is looking like the custom paint on the new fairing set is just about done to his standards. He is looking at 10-14 days until completion of their part of the refurb and upgrades, with shipping to take place by a bonded and insured, motorcycle only, shipping company within a couple days after that. Should get some pics from Tim next week. I highly recommend Tim and his company, the man is a perfectionist and all of his machines come with all of the proper customs paperwork and US title with the correct number of digits VIN for easy registration. All you have to do is transfer the title from VA to your state....unless you live in CA and it's a 2T. For my RVF, I was quoted the whopping sum of $45, no inspection required, through a third party AZ DMV outfit that I use.

    We were talking about a possible NSR250SE MC28 that might become available soon as well. The poor guy who was having it built crashed his other bike and might not be able to complete the full payment. I feel horrible for the poor buyer who might have to lose his deposit, it will come with a new HRC PGM4 ECU and deristricted key card, new crank and top end, full aftermarket exhaust, full dyno tuning and new bodywork with the OEM bodywork safely packed away in boxes for storage. If the poor guy can't pull the cash together to make the sale then I'm probably going to take a good hard look at it as an investment. Right now I'm next in line, and it's mine, if it falls through on the poor guy and I decide to pull the trigger. I think it might look great next to my supermoto in the dining room, rofl.
     
    Last edited: Nov 21, 2018
  20. NorcalBoy

    NorcalBoy Member

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    it was Christmas today for the RVF400 project, a bunch of stuff that I had been waiting on, arrived today from the UK.

    [​IMG]

    Ignitech programmable ignition with software, so my tuner here in Tucson can make changes, if necessary. It came pre-loaded with Rick Oliver's custom ignition mapping for my machine in it's current configuration...it will get checked out on the dyno and verified.

    [​IMG]

    Custom made Hyperpro CSC steering damper. It only took 2 months to get it from Holland to Rick in the UK, then to me, LOL.

    [​IMG]

    Also from Rick Oliver, his custom reverse damper mount...gonna have to replace those steel screws with some ti....

    [​IMG]

    Mosfet RR with upgraded wiring and connectors

    [​IMG]

    NGK HT leads for the new coils

    [​IMG]

    Upgraded ground circuit wiring from Rick Oliver

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    A grip of OEM parts to replace all of the bearings, seals, bushings and bolts in the suspension linkage and swingarm pivot. Also new valve cover gaskets and breather gasket for when the valve covers get vapor blasted and coated with cerakote. Replaced all of the eccentric hardware and seals with either new OEM hardware or ti, if it was available. Also replaced all the tank and fairing mounting rubber bits and bushings with new OEM.

    [​IMG]

    Random shot of some more ti hardware and the aluminum fairing stay. Waiting on an order from Titan Classics in the UK, as all of the fairing bolts are getting replaced with titanium versions of the stock Honda bolts. Have pretty much replaced all of the hardware on the entire chassis with ti. I have the pick sheet to do all of the engine cases, but I haven't ordered them yet...just want to make one last order to fill in any that I have missed, after I know I have everything, I'll make the last order and wrap it up. Have one more large OEM parts order coming from David Silver Spares and that should be the last of the OEM parts...unless I missed something..

    I basically just combed the entire parts fiche and ordered everything that was available, matched up all of the steel hardware to ti stuff, because the parts are getting scarce and I wanted to end up with an almost brand new machine, retro modded as close as I could get to today's Moto2 based tech.

    Machine is supposed to be completed this week by Speedwerks in Delaware, they are handling the refresh service, tuning for the Tyga carbon airbox, pipe, and filter, the custom painting on the new bodywork, powdercoating of the wheels and the new Diablo Rosso Corsa tire mounting. It should arrive in 9.5 out of 10 condition and all I will have to do is perform my mods.

    ProBolt USA
    Rick Oliver NC 30/35 UK
    Titan Classics UK
    Hyperpro NLD
     
    Last edited: Dec 17, 2018
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