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Old 12-02-2013, 09:00 PM   #1
Pezz_gs OP
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Joined: Nov 2004
Location: Sydney Skunkworks
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RG250 Mark 1 Dual Sport

G'day all,

I am about to start to build a bike for a fundraiser I run for Down Syndrome NSW and Australia called the Scrapheap Adventure Ride. www.scrapheapadventureride.com.au

Basically you have to buy a bike for less the $1000, fix it up and make it roadworthy, the ride to a destination and we have a party and fundraising night. We have raised over $220,000 over the last 4 years. I have ridden my XR460/4 which was a CB400/4 which I converted to Dual Sport. Build thread in my sig line

For 2014 I am building a new Scrapheap bike ad have been given this nice RG250 and will be planning some pretty decent suspension mods to get it ready for some dirt action. I planned to pick up a 1986 DR600S for the swingarm and linkage and hoping this will fit in the back of the RG frame.

I plan to keep the engine stock as it will go plenty quick enough for a dirt bike :)

Pezz :)









My bike from last few years below.



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Pezz_gs screwed with this post 12-02-2013 at 09:23 PM
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Old 12-02-2013, 09:03 PM   #2
Pezz_gs OP
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Well I think ebay was kind

I picked up this 1986 DR600 Dakar for the sum of $184.50

Both Bikes run a full floater rear suspension setup and I had hoped the rocker pivot is the same distance on both bikes. Long shot I know, but they were 20mm different

I really want to make all the mods reversable on the RG.





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Old 12-02-2013, 09:08 PM   #3
Pezz_gs OP
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Well . . . . .

When the RG has arrived at the Skunkworks. I had it sitting in the shed next to the donor bike. It is a tiny bike. I have taken a few rough measurements and looks like the complete DR600 Front end will need to be bolted on. Had a look at the DR front rim and it has numerous cracks and will need replacing too. Then a closer check of the rear wheel and it has two big flat spots opposite each other .

Looking at the rear floater suspension rocker pivot and the differ by about 20mm. I may just use the RG swing arm and stick the DR rocker in and see how that works. Then get a heavier spring for the RG shock.

I put the 7lt Nomad tank on the rear seat and it fits right in there

I have to pick up a box of other bits from Andrew this week and then I will see what I have.



That photo is not a true representation of the bike. There is much not servicable. Forks are rusty and pitted, most of the fittings, bolts and brackets are missing, it also has clutch issues, no airbox, no sidcovers. Basically a perfect place to start building a Scrapper

Also I am not cutting anything! Even the XR460/4 could easily be returned to a stock CB400/4. I have boxes of the original bits for that bike in the shed.

The Full Floater rear end is a bolt out and swap in. The tripples from the DR600 will slip right in the front end along with the forks etc.



The Fairing panels are sitting there held on with tie wire.



Let the DR teardown begin

I intend to use the front end and as much of the rear suspension as possible



Forks out now to the back end



The rear axle was a bent tent post.



The Full Floater out



Whats left, to go back on flea bay

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Old 12-02-2013, 09:11 PM   #4
Pezz_gs OP
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So, I got the RG up on the bike lift.

A few things to cogitate here . . . . .

Looking at the front end, the RG triple trees have a decent amount of offset, so I will need to do some basic trigonometry after some careful measurements to work out of the DR600 forks will suit.



Went and picked up a boot load of spares including spare tank, some sidecovers, engine sidecovers, a clutch, 2 x wiring harness's and a couple of spiders and 14 cockroaches.

Best of all a stock airbox!!

I want to run the stock setup as I will be riding on dirt roads



Once OldDog and I installed the front end we thought we would put the panels on and check for clearance issues
Need to remove some excess bits off te lower tripple clamp. Also move the Radiator down about 12 mm.

On initial measuring the front wheel wont hit either the header pipes or the Radiator



A few more from other angles. Steering head angle looks to be less than 30Deg but will be adjusted during the build. The screw drivers will be removed before its finished :)



The rear end is under contemplation next. Seat height will be around 880mm



Thought I would include some pictures of the RG without the body work.

The front end looks pretty straight forward and I can do some adjustments to get the geometry perfect.



I now need to focus on the rear end and coming up with a rear suspension that wont destroy me or the bike



Not a lot of space in there above the airbox. The swingarm will have to be extended to about 600 - 620 mm to make it work.



PS: Most of this was posted in my thread in the Oz Forum and as I am now startng the 'Build' I am placing the infomation here.
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Old 12-02-2013, 11:05 PM   #5
brianwheelies
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Very cool! Keep the pics coming!
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Old 12-02-2013, 11:43 PM   #6
michael1968
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Subscribed!
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Old 12-03-2013, 01:26 AM   #7
PhiSig1071
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I think this is going to look very cool with the fairing still in place. Very old school dakar. I can't wait to see the finished product!
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Old 12-03-2013, 03:57 AM   #8
Quacamole
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Offtopic

Off the topic, but I'm in Sydney now for a year, been searching without luck.
Where can I buy bike less than 1000$?

Cheers mate!
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Old 12-05-2013, 01:19 PM   #9
Pezz_gs OP
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There is a great thread in the Oz forum about 2 stroke Adv Bikes - Good read

http://www.advrider.com/forums/showthread.php?t=643957

Quacamole - PM sent
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Old 12-05-2013, 05:35 PM   #10
zig06
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I want one!

I am sooo envious of anyone that has an RG250, some day I'm going to be envious of myself!
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Old 12-22-2013, 11:02 PM   #11
Pezz_gs OP
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Finally got the RG swingarm out and got a chance to do some measuring . . . . .

The RG's alloy swing arm is very light, I can see why the can crack . . . .

A quick measure of its width at the swing arm pivot was 190mm. D'oh . . . .





The DR600 steel swingarm is 210mm width, and is substantailly heavier than the RG.

The plan from here is to take 10mm of each end of the DR600 swingarm, remachine the bearing races, and possibly make some bronze bush's with grease nipples.



I am still going to extend the swingarm 100mm, and lower the bottom shock mount 17mm.

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XR460/4 - http://www.advrider.com/forums/showthread.php?t=497905


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Old 12-23-2013, 12:15 AM   #12
jese
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Very cool build, can't wait to see how it comes together!!
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Old 12-23-2013, 12:58 PM   #13
OldDog
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The madness continues! Rock on Pezz. Can't wait to see this beastie out in the bush
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Old 12-24-2013, 07:53 PM   #14
PeterW
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Looks fun, though, remember those bikes had a bit of a drinking problem. What's the maximum distance between fuel stops ?

Pete
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Old 12-26-2013, 11:30 AM   #15
Roadracer_Al
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