Project: Cafe 2 Pump Chump (77 RD400)

[xjoey dubsx]

Got the exhaust off today, broke 3 other bolts, gotta get some heat on the studs and remove them..

 

[xjoey dubsx]

DG exhaust is ordered! Should have thursday

 

[JustinLonghorn]

I like me an RD.

 

[codys1024]

nice i was going to try and get a DG exhaust for my rd200 but they wouldnt fit for the 2 stroke , did you get the all black ones ?

 

[xjoey dubsx]

nice i was going to try and get a DG exhaust for my rd200 but they wouldnt fit for the 2 stroke , did you get the all black ones ?

Yep, these ones.

Found them cheap at chappapals or whatever it's called, but it wasn't in stock.
Dennis Kirk beat the price by a dollar, including shipping, when I told them about their lower price, and they had it in stock.
Satisified buyer so far!

 

[xjoey dubsx]

We sell Rigid Dually lights at work, and been thinking about buying a single driving and single fog light and making them my headlights..
http://www.4wheelparts.com/Lighting-and-Lighting-Accessories/Rigid-Dually-Series-LED-Lights.aspx?t_c=14&t_s=448&t_pt=101155&t_pl=102685

Mocked up on mine:

Photoshopped another, nicer RD400 to mock it up. Being I still have gauges, don't have clip on's installed yet, it's a before picture, I wanted a better idea. I do like the number plate/windscreen idea..

Opinions?

 

[bradj]

No no no no

 

[bradj]

No! please no.

 

[xjoey dubsx]

Got my exhaust and clip ons today!

Then got motivated and tore the engine out, all the wiring, and so forth.

Next is to power wash it, get all the grease off, then take off wheels, forks, swing arms, and paint the frame.
Thinking about using POR15 on the frame, rather then blasting and powder coating it.

 

[xjoey dubsx]

Scary tracker tires,low C.O.G.,clipons,slammed forks and a peaky noisey old RD.I love the concept to just ride around the block just to piss of the neighborhood.But to think you can go for rides on it and enjoy the experience and survive? Having lights that probably won't throw a decent straight beam to see where you will be in two seconds? RD's can be great handling smokers with grunty motors but most of those qualities will be lost the way you are going.

Tires will be replaced, they are the ones that were on it when I got it.

Low COG, which is what I'm used to from rockets.

Slammed forks? Not sure what your meaning by slammed, but rebuilding them, the seals are blown out.

Noisy, what bike isn't? Loud pipes save lives..

I had the drag bars on it, and it road nice, doing Clip ons with a lower seat shouldn't offset too much.

As far as lighting, you must not know Rigid lights..
First watch this..
http://www.youtube.com/watch?v=wuIU-Mg0EMM

Then this..
http://www.youtube.com/watch?v=kdl1HW0_vfU&feature=related

Then this..
http://www.youtube.com/watch?v=f89saxnf6VQ&feature=related

I'll be able to see.

I work at 4wheel parts in cleveland, I've never sold a set and had a customer unhappy with them.
Also, we have a display spot light, which in a good lighted day, with our lights on inside, you can still see this hit the opposite wall, maybe 500 feet away?

This bike is not going to be for hours on end riding, but for shows, events, and putting around town. I live 5 minutes from work, so I'll ride it to work, and to bike nights but it's for looks.

I do appreciate the opinions and input though, don't take my response the wrong way.

 

[xjoey dubsx]

Oh, gotcha. Yeah, not doing that.
Got a bagged truck for that.
Didn't even know you can do that, makes sense..

And as far as noise, ehh whatever lol. My whole neighborhood is loud.

 

[xjoey dubsx]

Well 3 of the 4 studs for exhaust broke off in less then flush .. One came out fine. Ended up plugging holes and powerwashing the engine and frame to get grease off. Next is to sand and paint.

Sent from my DROIDX using Tapatalk

 

[xjoey dubsx]

Tore down the frame the rest of the way. Just need to sand or blast it, and going to POR it.

Then blast and powder all the small parts.. Getting excited!

 

[xjoey dubsx]

Took my engine to work yesterday and one of the techs stayed after and tried to extract the bolts. No luck, but we got one drilled and tapped.

2 to go!

Today, I sanded the frame down to bare metal today, then hit it with some POR15.

Going to scuff it up and hit it with POR15's Blackcote over it tomorrow night.

 

[xjoey dubsx]

I reread the first post you did. This RD is not a bike that you can ride a low revs in the low or high gears.
Unless it has worn out piston rings, clogged mufflers or it is very badly out of tune the “no power down low and then it screams at higher revs effect"is quite normal for a sports two stroke motor.
At a guess the motor would start making serious power and screaming at about 6.5K RPM and not much power at all below 3K RPM.
It has a 6 speed gear box for a reason: to keep the motor in its “power band”.
It needs the right high quality spark plugs of the standard heat rating.
For reliable running and easy starting it is essential to use quality MC TS oil (ideally synthetic).Drain out any cheap outboard or lawnmower oil in the oil tank.
It needs high quality sports tires of the same size as fitted as stock to be safe and stable.
This model was the 911 Porsche of the road bike world from the mid to late 70's.It needs to be treated with respect. On a twisty road with a talented rider it would go faster than bikes nearly three times its motor’s size.
Unless you have the tuning data and experience needed to tune it to run the carbs with high quality single air filters leave the stock air box on with a new filter.

I am not keen on carbs by any mean.
I am going to have someone help with that, but found this link and a few others.... Should help me I assume.
http://www.motocarrera.com/advice.htm

 

[xjoey dubsx]

Engine is back home, had one of the guys at work drill out the last two broken bolts, and retap them.

Took some parts to my buddy to powdercoat, including the triple trees, kick start and brake pedal.

Noticed that when I was knocking the sh!t out of it to get the old bearing race out, I messed up the threads on the top of the triple tree, so that took a few hours today to rethread.

Also, buddy made a judgement call that he shouldn't coat the top in the center of the upper triple tree, so I hit that with the BlackCote.. Worked well and matched up.

Pressed the races for the bearings in the frame for a test fit then put the triple tree back in.

Then started on painting some small parts I'm not going to powder coat.
Battery box, chain guard, engine side covers(not pictured) and swing arm pieces(not pictured)

Waiting for my bottom tubes of my forks and clip on mounts to get done powder coated, then I'll be installing the clip ons, forks, fork boots, and headlight mounts.

Next he'll have my shifter to powder coat, and my wheels.

Gotta get around to order the brake caliper rebuild kit, seals for those side covers I took off, and some other stuff.

 

[xjoey dubsx]

Got some more parts back.
Front end loosely mounted...

 

[bradj]

It may sound harsh but I know I'm right.

what a fucking dick

 

[FlyinRyan350]

There is absolutely no reason to be that dramatic about it swivel. Moto Carrera, HVC, DG, and numerous other places will tell you what jet sizes to start at when running different intake or exhaust. They aren't going to get you exactly perfect but if you start on the rich end and work your way down anyone can tune carbs.

Here's the link for moto carrera's page that lists there recommendations. It's about 3/4 the way down.
http://www.motocarrera.com/advice.htm

 

[xjoey dubsx]

Got the rear swing arm on, shocks on, and so forth tuesday.. Really thinking I need to powdercoat the springs..

When it comes to carbs, like I said I'm going to get help with that.
Probably take it to Pride of Cleveland since I know some people there.