1994 RVF400R Build Project

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

  1. NorcalBoy

    NorcalBoy Member

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    That is awesome, Mr. Pete. Glad to hear that everyone is getting their stabby naps and not having any side effects.
     
  2. Gator

    Gator Insider

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    Weight savings on big spinning objects are a really good thing! lol

    I got the Pfizer, my arm did get sore last night, kind of like a tetanus shot. No other side effects yet.....
     
  3. NorcalBoy

    NorcalBoy Member

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    Got back into the garage early this morning, while it was still cool, calm and quiet. My buddy had a work thing and couldn't swing by until later in the afternoon to get the assembled bits down at a safe level, before it got to heavy.

    Decided to pull out the new Tyga aluminum subframe and started mocking everything up to check clearances for all of the items that get bolted to it. I always suspected that the OEM subframe was slightly bent, as it was a bitch and a tirade of expletives to get it all stressed into the mounting points. Eventually, I knew this would destroy the aluminum threads in the frame, which I didn't want to go down. The Tyga part is a quality piece, and constructed mostly from solid bar, not square tube, unlike most aftermarket aluminum subs I have seen.

    As suspected, with a little bit of coaxing, the Tyga sub mounted right up. The OEM sub I had powdercoated white, the Tyga sub came pc'd black. The black ended up being a perfect match to the frame powdercoating, so I left it black. I don't know how much weight was saved vs. the steel OEM sub, but I know it was quite a bit.

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    Next I started checking all of the mounting locations for the remote shock res holder, reg/rec, and the exhaust hanger. I had a few clearance problems in this area before.

    The Tyga carbon remote res holder mounted right up and the ti bolts I already had were a perfect fit, no problems.

    [​IMG]

    Moved on to the RR and the exhaust mount...that's when things got interesting, lol

    There was not enough clearance for the larger mosfett RR that I'm running and the exhaust hanger. This was also an issue with the OEM sub, but I was able to work around it, but I had to install the hanger first, then the RR, and once the RR was mounted, you couldn't remove the hanger without taking it off. Not exactly top shelf, and I decided to do it the right way this time. Made a few marks on the RR fins and headed to my buddies shop to fix the problem.

    Rob used his CNC mill and removed the fins on the opposing corners (didn't know if I would end up mounting it with the wires coming out the top or the bottom) to create the necessary clearance.

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    Got back to the garage and tested it out, perfect fit. The next pics show it was definitely the way to go. Now the hanger can be removed without monkeying around with the RR. Everything mounted up with the ti hardware I had used on the OEM sub, which saves some money and time.

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    So that fixed that. I was also able to drop off the new Tyga upper cowl stay and the chain guard bracket at the powdercoater on the way to the fab shop, so I should have that back late this week, or early next. I tried an aftermarket style chain guard that didn't utilize the OEM bracket, but it was flimsy and actually sustained a little damge on the only ride I took it on. The new one is an exact replica of the OEM chainguard that I found in France and had it shipped over. Much nicer piece.
     
    Last edited: Apr 5, 2021
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  4. squirrelman

    squirrelman Member

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    :Nod:

    you should be working for NASA or Spacex :Smile:
     
    Last edited: Apr 5, 2021
  5. NorcalBoy

    NorcalBoy Member

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    Thanks, S-Man, but that might be a bridge too far. :Nod:
     
  6. NorcalBoy

    NorcalBoy Member

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    Made some additional progress this evening with the electrical and some cooling system stuff. Starting to pick up a little steam.

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    Next on the agenda is removing the sub, getting the rear engine flap in place, then reinstalling the sub properly and getting the fender in place so the rear half of the electrical can be completed. Unfortunately, dealing with other stuff tomorrow that's gonna put the brakes on it again.
     
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  7. NorcalBoy

    NorcalBoy Member

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    Not much to report today. Spent the day dealing with a few issues with my truck. Won't go into details, but I ended up being pretty damn happy with the way all that ended up.

    But tonight, I did manage to jump one of the hurdles that needed to get cleared so that the rear of the bike can be assembled and the electrical can get completed. The Tyga sub requires a small bit of "massaging" if you want to use the OEM fender, which I definitely wanted to do. Paul at Tyga supplied me with the measurements for where it needs to be trimmed to fit the different cross member. It's not much really, but I wanted to do a clean job. Tonight I got it done.

    OEM sub and cross member:

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    Tyga sub and cross member:

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    After getting the notch removed and the edges all cleaned up, I'm pretty happy with the fit. All of the mounting holes lined up perfectly and the fit is really clean. Very happy with it. This sub is tailor made to work with the Tyga one piece rear cowling that I bought. The weight savings are in the neighborhood of another 3-4 pounds with this combination. With this combo and the wheels it's likely that it's an 8-10 pound savings just in these components. I'm gonna have to find a good scale to get an accurate weigh in when this thing is done.

    Tomorrow morning I will get to work on getting the sub, fender, and wiring all permanently in place and everything torqued to spec. I had been wondering how hard it was going to be putting it back together after 2 years of not even looking at it...I've actually surprised myself by how well I learned it during the first assembly, and even more surprised by how much of it got retained by my little pea brain.
     
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  8. skimad4x4

    skimad4x4 "Official" VFRWorld Greeter

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    Great to see it coming together.

    I must admit I have never seen a stand like that before. I cannot make out if the bike is just resting on the stand or is it also securely bolted to the stand?

    After all the work you have put in getting the parts into pristine condition I would be rather scared just in case I added a bit too much weight at one end of that see-saw and turned around to see the whole thing suddenly tip up or worse still fall over.
     
  9. NorcalBoy

    NorcalBoy Member

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    It's sitting on the base and is quite solid, up to a point when you start adding a bunch of weight to the rear, at that point you just add a stand to the swingarm and it's fine. There are a specific set of assembly steps that seem to make such a simple thing work so good. This will be the second build off that stand, the cost of a 2x4 and some screws has paid for itself.
     
    Last edited: Apr 8, 2021
  10. NorcalBoy

    NorcalBoy Member

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    Got in a little more time in the garage.

    Got the wiring harness and all of the electrical bits installed. This is what I call "fiddly" work, as it's a lot of careful wire routing and getting things secured. This is probably the most time consuming part of the entire assembly.

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    Installed the single seat cowl and checked all the clearances to the bodywork. Thankfully, everything was sitting nice and the bodywork wasn't being stressed anywhere. With an entirely new subframe, I have to say I'm very impressed with the Tyga sub. Everything fit up exactly like OEM, with only one small modification to the fins of the RR. Tyga Performance is a great company for the RVF mod community, without them, a lot of this stuff wouldn't be available. You definitely get what ya pay for.

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    This morning is tax time, so I'll go deal with that and see what I can get accomplished after that.
     
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  11. KarlR

    KarlR New Member

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    Looking good NorCal. After all the time you put into it the first time around I figured you would remember how to put it back together.
    I still like the engine color every time I see it.
    Sounds like you are back in the mood to work on this project.
    I just did an r&r on the VF500 front brakes and found myself thinking ‘what would NorCal do’?
    Thought you would get a laugh over that.
     
  12. Gator

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    And here I am moaning about having to pull the upper injectors off my CBR 1000 track bike and clean them...........
     
  13. Gator

    Gator Insider

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    Thats what happens if you don't go to the track for a whole year. F 2020!!
     
  14. NorcalBoy

    NorcalBoy Member

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    If you aren't feeling it, just putting air in a tire can seem like a big project. :Laugh:
     
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  15. NorcalBoy

    NorcalBoy Member

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    Spent the last couple days working through a few little issues. The rear brake just wouldn't bleed correctly, rather than waste a bunch of brake fluid, I pulled the whole damn thing back apart, disassembled the rear caliper and the rear master completely, inspected every piece, put vibra seal on the bleed nipple for the caliper and let that set up, then put them both back together. Bench bled the rear caliper and the master, prefilled the brake line, and reassembled the entire system. In about 20 minutes, I had a perfect lever. Odd actually, never did find anything out of the ordinary.

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    This morning will be getting the axle torqued up, getting the chain in and adjusted, and wrapping up the left side of the engine....then on to radiators, meters and triple clamps. Didn't think it was possible, but it might actually make it to the tuner by the end of the week...just need the pieces back from the powdercoater.
     
  16. Diving Pete

    Diving Pete Member

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    loving it - when you are ready to start it, can you video it.....?
     
  17. NorcalBoy

    NorcalBoy Member

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    Got little more done this morning. It's coming along OK.

    Torqued up the rear axle, installed the chain and got that adjusted up, installed the shift linkage and got that set, buttoned up the left side of the engine.

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    Went to install the steering stem, and whoops....threads not cut correctly. Texted my CNC guy and told him we had an issue. We chatted back and forth and he decided he is just going cut a new one on Monday...bummer for him. The bummer for me is that I had to postpone getting the exhaust and radiators finished. Whatever, moved on to other stuff.

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    Intake porting by Mike Norman

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    Got the carbs installed, got the choke, throttle and idle cables all hooked up and adjusted

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    Decided to take a break until the sun goes down and the Atlanta 1 supercross is done. Left it here:

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    Tonight I'll try to get around to setting the meters and getting the speedo drive and cable hooked up...then I'm not really sure what I'll do next, maybe airbox. It's almost like I blinked and it was almost finished and ready to head to the tuner. Kinda surprised myself, as I wasn't even really on a mission, just putzing around and jamming tunes and putting the puzzle together.
     
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  18. Jim McCulloch

    Jim McCulloch New Member

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    That's funny, I work with NASA and SpaceX quite a bit and they are hiring!
     
  19. Jim McCulloch

    Jim McCulloch New Member

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    Wow, that bike is going to be a feather weight when done. Incredible build!
     
  20. NorcalBoy

    NorcalBoy Member

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    Thanks, JM. It would be nice to finally get this thing over the finish line. That triple stem being incorrect kinda mucked things up, would have had it done by Monday. I only have a week left. otherwise it sits again.
     
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