Project Daytona

Engine Tuning & Development - Performance Parts

All Enquiries mail: mark@suzuki-rg500.com

Scott Rehl's Motor
Codename "Project Daytona"

Or in other words "Can you build me a motor and pipes in three weeks outputing 140+BHP"

"Come on........give me a challange!"

The reason for this madness is so Scott can enter into the AMI dyno shootout during Bike Week at Daytona, alongside Randy Norian and his AMI winning RG500 Delta, and hopefully wipe the floor with the 4-strokes.

With very little time to dial the bike in before Daytona it'll take a lot of work.

"And a lot of beer!"

Hopefully this page will be completed within 3 weeks, click on any picture to enlarge.

Motor Ready to ship from the USA	Motor arrives in the UK	Before stripping the motor, all specs are checked as the motor is dismantled.
I just can't beleive tuners spend time porting the inlet and just don't bother shaving the RV????	There's a surprise - Wiseco's	In fact.........4 of them!
Not sure what this plug is for on #1	Crankcase stripped	RV cover friction material has lifted, could of been nasty.
Recutting the pick up notch on the crank web to allow the extra advance needed for the Wolf CDI.	Pick up notch before and after

After measuring the motor this is what i found

Disc Timing - open 147deg BTDC, Close 54deg ATDC
Squish - Ranged from 0.052" to 0.042"
Head volume - 8.7cc
CR - 8.21 : 1 or if you prefer 15.32 : 1
Ex port from deck - 25.5mm x 43.3mm wide!!!!!!!!!! ( work the width bore on that sucker?!?)
All transfers have been leveled at 39.9mm from deck
Ex duration - 193.67deg
Trans duration - 125.22deg
Piston bore clearance were rougly all the same
Bore measures - 56.05mm
Piston measures - 55.93

This is what i plan to do to the motor

	Big bore conversion
	Full engine tune
	Rebuild crankshafts
	TMX 38mm conversion
	Billet disc valve covers
	Custom GP style exhausts
	Programmable ignition Inc. TPS
	Bottom end gas flow
	Straight cut primary gears
	Adjustable SAEC controller

From here on i will document all modifications i make to the motor as and when they happen.

TMX 38's, these should be able to suck small children into the motor	Inlet jig fabricated to suit area of the TMX's	Inlet port - Stock V's modified
Exhaust port jig fabricated to suit the new port dimensions	Exhaust port - Stock V's modified	Lower pipe template, total of 26 cones to fabricate this pipe!!
Inlets re-worked to suit carb bore area.	Upper crankcases flowed and completed	Only attempt this if you have an understanding wife!
InnerRV covers machined to match ports	VIDEO. Click to see cones being cut	No prizes for guessing what these are going to make!
Looks just like the drawing!	This is going to cost you a lot of beer Scott!!!!	Pipes tacked and fitted to the bike. These should be shown in an art gallery in the highly sexual section!
Another view of the lower pipes	Oil injectors made and fitted to the TMX's	Battery Box/Oil Tank fabricated
Final welding of the lower pipes	Lower pipes completed	That should do it!
Suppose i'd better do the top pipes now!	Cylinders bored to suit 59mm pistons.	Cranks are now re-built with new seals, bearings and rods. One of the crank webs had to be replaced.
1st of the top pipes tacked up.	Top Pipes finished :o)	Busted my ass!!!
Just hope that 160 hoop fits in between!	Carbon RV's, less rotating mass	Clutch hub totally shagged. Click here for a little video of it
Cylinders are now ported and complete.	Jig to measure squish and compression ratio	Cylinders are decked to account for the smaller piston pin to crown height
A sorted clutch! Straight cut primary's and oil holes drilled, this together with Kevlar plates makes an awesome clutch.	Heads fully machined	Billet ally exhaust flange with St/St spring bracket.
I've got stock of these!!!!!	Now........ain't that pretty :o)	Pipes are finally complete.
Outer RV covers have now been ported	Carb spigots have inserts to reduce to a M6 bolt fixing	Engine has been masked ready for painting tomorrow.

So that's basically it, all the hard work is now done, with the exception of making the wedge to tilt #3 carb.
This is the part that gives me the most satisfaction, rebuildng the engine.
I can start and finish the rebuild with clean hands!!

Bottom end rebuilt, new fasteners are used throughout the rebuild.	Carbon RV's completed	RV's installed
Almost there! I'll fit the carbs tommorow :o)	Engine complete Left Side	Engine complete Right Side
Throttle position sensor mounted on the oil pump	Front View

Sorry for the delay in updating this page but what with one thing after another i just havn't had time, sorry.
I've had a lot of people mail me regarding the outcome at Daytona, unfortunately it didn't go quite as planned as we had an ignition gremlin that detonated one of the cylinders, on the plus side Randy Norian once again took top honours with his RG500 Delta posting a 'Whopping' 132bhp at the rear wheel with 2nd place honours going to a modified GSXR750 reading 122bhp at the rear hoop.

Scott sent the motor back to me to rebuild to sort out, this time i've rebuilt the motor and fitted it into my chassis so i can set it up on the dyno.
The rebuild went very smoothly with actually not much damage

it really does look worse that it is ;o) !!!!

Anyway, the motors now fitted in my chassis and a base run has been made on the dyno after running it in, the motor still has to be dialled in properly yet so should add at least another 15hp on the top end :o)

Here's Scott's motor fitted in my chassis

Here's Scotts base run V's a Kawasaki ZX-636R
Click to enlarge.

CLICK HERE TO SEE A SHORT DYNO RUN VIDEO OF THE BIKE

More to follow!