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VFR to RC45 "ish" replica budget build


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Should change the name to "Project Q" Hope everyone is healthy and doing well.

Redesigned the front support in order to mount the headlight, overflow bottle and gauge. Also wired up and modified new switch so I have headlight OFF/ON/HIGH from one light. Got rid of a lot of unnecessary wiring throughout... amazingly I managed to get everything to work even though I hate wiring.

 

 

 

 

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Been on here randomly for a few years just asking dumb questions. Sold my rc51 and my crf450 supermoto before I got married 7 years ago (Big mistake! Not the marriage part but selling my bikes. I want

Figured out a work around since I couldn't machine the hardened steel linkage bushings. Bored some bronze 3/8" bearing sleeves to accept the M10 bolts and drilled out the suzuki plates to 12.5.-12.75i

The majority of the fitting and tacking is done for now. Next will be adding the dual exits to that last collector. Alot of grinding before welding those in place. Then it'll be the link pipes to the

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Also decided to go with a 4-2-1-2 exhaust. Mocking it up now... pics soon.

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Nice work!  

 

what did you use to make the "scoop" around the headliht? Much trial and error to get the angle at the front right so it fits snug to the faring?

 

 

 

 

Luckily for me, the headlight on my project is A LOT easier.... :goofy:

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I think I used a pvc drain adapter 3-4" I believe. A lot of measuring and making paper templates to get in the ballpark. Finally decided I was close enough, traced it, and just cut the thing and crossed my fingers. If I screwed it up they're only a couple bucks. Luckily it came out really close. Top touches and the bottom has a 1/8 inch gap but you can't really see it. Thanks for noticing the difficulty in not just the bucket but also drilling the 3 5/8 hole and getting everything to line up. So glad I didn't screw it up.

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Interesting project.  The 4th gen frame is probably the closest in looks to the RVF's frame.  I hope you're going to get those brackets welded at some point...

 

I see that the RVF Project guy used a swing arm from a 99-05 Aprilia Falco, but he said it needed to be modified (not sure how much).  I was interested in doing something like that.  I was going to try a Blackbird swing arm, but having an RC30 one is probably bling enough...

 

Ciao,

 

JZH

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Thanks. The support bracket is fairly sturdy as is, a little locktite on the hardware will do the trick. For now I'm running the SSSA but at some point I may try to do a conversion. In the meantime I'm going to rock this...

 

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Don't mind the mismatch cans. Got another chinese one like the right coming soon. I know is just for looks but I always wanted a dual high mount for my RC51 which I never got a chance to do.

 

Also, I decided to make the tail and tank cover a one piece deal. Comes off with no tools in a few seconds once the ram tubes are disconnected. Stripping the whole bike takes a couple minutes tops.

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Great project, thanks for posting.

I just got my Airtech-Streamlining RVF750 fairings on Monday, so I am just starting the adventure.

Thinking of using dome head Dzus fasteners; what are you using for fairing fasteners?

Brian

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Cool! What do you think of the quality of the Airtech fairings? Pics? I went with Sebimoto and I'm not really impressed with the quality and fitment. Nothing seems straight and very thin in some areas.

 

I'm using quik-latch fastners for the upper that mount to the frame and Dzus style for the lower. I'm not really a fan of the dzus, they seem sloppy no matter what I do. I'm thinking of changing them to a calder pin style which I'll have to make myself.

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Well, I'm about to take the carbs off to clean the jets and circuits because they are so clogged the bike can only idle.

 

In previous posts, some members suggested to run a line for atmospheric pressure to the airbox to account for the slight ram air effect. I'm using the big line that went to the little filter outside the airbox and now rerouted that to the PCV inlet on the airbox "which is filtered by the airbox element". Pic below:

Is this correct?

My main question is what are these lines and what to do with them? (they have the blue painters tape on the ends) I believe they are from the air injection lines from the emissions pumps from the exhaust. Since I got the bike they have been open and the bike ran well. Should I plug both, join them by putting a union in, or put filters on them?

 

 

 

 

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Those should be just your carb vent lines and need to remain vented to atmosphere.  You can just make sure they point down so nothing gets in or install a filter if you want.  You could join them with a T and run to something like this too.

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2 hours ago, Captain 80s said:

Those should be just your carb vent lines and need to remain vented to atmosphere.  You can just make sure they point down so nothing gets in or install a filter if you want.  You could join them with a T and run to something like this too.

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Thanks for the help! I thought the big one that I routed to the airbox was the vent line. Any idea what that does or just another vent?

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The little one in back is def carb vent, you can see it attached to the T fitting on the carbs.  On my 86 VFR, there is a separator/breather on the rear Valve Cover that routes to the air box there.

 

I did have a problem routing something similar on the first 86 VFR Cali bike I de-smogged.  There is an extra spigot on the front of the Cali bike airbox and I routed an extra breather hose (larger like that) there.  The rush of intake air created a vacuum at that spigot and totally fucked with carburetion out on the road.  Took me a while to figure out what I had done.

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11 minutes ago, Captain 80s said:

The little one in back is def carb vent, you can see it attached to the T fitting on the carbs.  On my 86 VFR, there is a separator/breather on the rear Valve Cover that routes to the air box there.

 

I did have a problem routing something similar on the first 86 VFR Cali bike I de-smogged.  There is an extra spigot on the front of the Cali bike airbox and I routed an extra breather hose (larger like that) there.  The rush of intake air created a vacuum at that spigot and totally fucked with carburetion out on the road.  Took me a while to figure out what I had done.

Ok, thanks. I quess I won't know until I actually ride it then.

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Anyone have a new 520 rear sprocket for a 4th gen? The only company I know that sells them have been waiting on their chinese supplier with no word on when they'll get them.

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2 hours ago, monstar said:

Anyone have a new 520 rear sprocket for a 4th gen? The only company I know that sells them have been waiting on their chinese supplier with no word on when they'll get them.

I have been waiting since OCTOBER for a 520 Steel VFR sprocket. Last I heard it was supposed to ship in April. I should have just machined it myself from a PBM sprocket blank. I can get Aluminum, but I want Steel.

 

So if you are really in a pinch and want a steel sprocket, that might push me over to making a batch of them. 

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4 hours ago, YoshiHNS said:

I have been waiting since OCTOBER for a 520 Steel VFR sprocket. Last I heard it was supposed to ship in April. I should have just machined it myself from a PBM sprocket blank. I can get Aluminum, but I want Steel.

 

So if you are really in a pinch and want a steel sprocket, that might push me over to making a batch of them. 

The vendor I was speaking of is sprocket specialists also and I ordered in November and they refunded my money in January. I would prefer steel but where can you get aluminum?

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2 hours ago, monstar said:

The vendor I was speaking of is sprocket specialists also and I ordered in November and they refunded my money in January. I would prefer steel but where can you get aluminum?

SORRY. My bad... I meant sprocket center! I'll give sprocket specialist a try, website looks like they do quality stuff.

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Anyway I cleared up what hose does what. A honda mechanic loosely confirmed. The large hose goes to the slides, the smaller one in the rear next to it go to the floats, and the one in the front is a vent to atmosphere. So I shouldn't run the slide to the airbox but to outside air with possibly a filter or protection of some kind. The front vent probably the same. The one from the floats should be the one that goes to the airbox "we believe" to pressurize the floats in theory.

 

Just pulled the jets out of the carbs and they are the stock jets as expected even though the seller said it had a jet kit, hahaha.

 

So, I can't find a jet kit that comes with needles and springs... All I can find are jets and shims.

 

Are needles & springs necessary? If not, what size jets should I run to get in the ballpark?

 

I'm pretty much at sea level, running a UNI foam filter and a pretty open and pressurized airbox and two brothers headers to dual 2" cans (4-2-1-2)

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Had to take a look around. Absolutely stupid. Vortex makes and aluminum rear. I have a used one. You can buy off their site. If you do the individual sprocket, they say they don't do a steel sprocket.

 

BUT...Go to SportbikeTrackGear, and right there, you can get a complete Vortex sprocket kit, with a STEEL rear 520 sprocket. What a scam. I know its an uncommon bike and all, but somehow you're only able to offer a steel sprocket if it's paired with a front sprocket. This isn't Noah's ark.

https://www.vortexracing.com/builder/#

https://www.sportbiketrackgear.com/vortex-honda-vfr750f-90-97-v3-chain-and-sprocket-kit/

 

 

Anyways, its PBI sprockets, not PBM. Blank steel sprockets or custom aluminum ones. 

https://shop.pbisprockets.com/product.sc?productId=548&categoryId=56

https://shop.pbisprockets.com/product.sc?productId=551&categoryId=56

 

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38 minutes ago, YoshiHNS said:

Had to take a look around. Absolutely stupid. Vortex makes and aluminum rear. I have a used one. You can buy off their site. If you do the individual sprocket, they say they don't do a steel sprocket.

 

BUT...Go to SportbikeTrackGear, and right there, you can get a complete Vortex sprocket kit, with a STEEL rear 520 sprocket. What a scam. I know its an uncommon bike and all, but somehow you're only able to offer a steel sprocket if it's paired with a front sprocket. This isn't Noah's ark.

https://www.vortexracing.com/builder/#

https://www.sportbiketrackgear.com/vortex-honda-vfr750f-90-97-v3-chain-and-sprocket-kit/

 

 

Anyways, its PBI sprockets, not PBM. Blank steel sprockets or custom aluminum ones. 

https://shop.pbisprockets.com/product.sc?productId=548&categoryId=56

https://shop.pbisprockets.com/product.sc?productId=551&categoryId=56

 

I don't know what the deal is but I bought a vortex aluminum from some company like iMoto or something and it did not fit 251AK. Trying to return it still. I searched vortex site after that and the don't make a 520 steel but an aluminum 249AK. I already ordered one through spocket specialist, oh well, just tired of searching and waiting and getting the wrong part.

 

Most of the stuff has been discontinued but these sites don't update their catalog and still list them or send you the wrong stuff!

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Hi Monstar.

Interesting work.

I 'm working on a similar project based on RC46 (VFR800).

All information that you will share are appreciated.

 

This is actual situation. My idea is swap swingarm with another one from a CBR for weight reasons.

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I'm also working on an RC46=>RC45 replica so all info on similar projects is of interest.

 

However I have NO intention of eliminating the Single Sided SwingArm as that is so much a part of what makes an RC45. Yes I know, they did try double sided at the end of its racing career, but it was never actually produced with that. For me, it has to be SSSA.

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Thanks luigi and BiKenG! I would love to see what you guys have done and are doing. I'll also try to post the progress with mine as well. I was kinda bad about documenting I as went but here is a list of things I have done, I can post pics if needed or answer questions if I can:

 

Suzuki front end (swapped out the 3 spoke for the vfr750 wheel)

Two brothers full exhaust

Silicone radiator hoses

New clutch and brake masters, braided lines, etc.

Danmoto cbr900 rearsets (modified, wouldn't suggest these)

Uni filter and ram air mod the airbox (emissions equip delete)

Sebimoto bodywork (not the best quality but cheaper than most)

Tyga tail/s subframe NC35 (modified to fit)

NC30 tank cover (tail and tank joined with custom brackets)

Custom fairing brackets, quik-latch fastners and endurance style headlight

Rewired everything, keyed ignition delete, trailtech gauge, tail light on/off switch, fan on switch (small spal fan to fit COP's)

COP mod using zx10r coils and custom harness (wired 2 in series and working on clutchless upshift)

Cerakoted engine cases and valve covers (deleted PCV breather by using a front valve cover on rear cylinder)

Custom Carb/airbox heatshield

Custom integrated led rear brake/turn signals and bar end turn signals w/ new 3 position headlight switch (off/on/high)

 

 

Working on:

Cleaning/jetting carbs

Finishing exhaust

trimming and cleaning up bodywork/tail fitament

Sorting out a quick disconnect ram air tube setup that looks clean

fuel cell

rear sprocket

etc.

 

 

 

 

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