Hi All
It’s been a while since my last post. It’s surprising on how many other things needed sorting with a Bike that’s been in boxes the last 20+ years.

However, I thought it time to give some feedback on our attempt in setting up the RC Valves of a MC28 Engine sitting in a MC18 R5K Bike.

Following Andy’s sage advice, I marked both the fully opening and fully closed RC Valve positions in RED (See Pic NSR250 RC Valve Markings) on both the rotating and static parts of both pulleys.

I tried to set up via the Service Manual (just as an experiment), but found that the RC Valves to be way out. The text in RED below is a partial extract for the DMR-JAPAN Pulley Product F27-21002 and I think the text 'The installation method is noticeably wrong!' is definitely referring to the standard Service Manual set up, not the procedure (if that makes sense!). The Manual was certainly not written for mix and match set ups that we are trying to achieve here.

If I had my time again (I think the saying goes, I wouldn’t start from here), I think I would modify the Pulley Back Plates (See Pic NSR250 RC Valve Mod 1); please forgive the basic drawing, my Tech Drawing Set disappeared many moons ago) by attaching a custom-built metal plate to each Back Plate with Markings Laser Cut into it, so that you could mark the ‘Back Plate Markings’ where the Fully Open and Closed positions were. This would not only be good to get it set correctly, but you could also see if the buildup of carbon is affecting the RC Valve operation.

I can definitely state that the slipping Clutch on the Pulley works fine, as my first experiment to set it all up, the RC Valve was fully closed, but the Servo wanted to close it just a tad further and you could see the Slipping Clutch work physically.

In the end I had to play with it to get it right and ignored the Manual, except for the actual procedure. One final point though I found setting up the Rear Cylinder to be a pig and I'm not sure it's right now.

Hopefully when it’s road legal it will be interesting to see how it all performs.

Will be interested on any views on this (please be kind lol).

Regards

Phil

Below extract FROM DMR-JAPAN
[The installation method is noticeably wrong!]
The method described in the manual to remove the sloposi and align the notch on the cylinder side is not acceptable.
(1) Servo motor is not set to Max HI.(about 3/4)
(2) RC valve is considerably closed from the fully open position.
If you install the wide pulley using the manual procedure, the RC valve will interfere with the cylinder!
Be sure to adjust the servo motor to HI with the servo motor at max HI and the exhaust removed so that the RC valve is aligned with the top of the port.

*MC18(Since the working angle is narrower than that of 21 series, please inspect it periodically.)
*There may be changes in product specifications due to manufacturer's reasons.