tleighbell wrote:
What is the TPS plug?

Throttle Position Sensor

tleighbell wrote:
And another less embarassing question: with an MC28 engine and PGM II, can i solve all these issues by installing R5K barrels and RC valves?

I doubt it.

R5/6K barrels are arguably better than MC21/28 barrels though, but with slightly less effective cooling.
_________________
Andy.
NSR-WORLD.COM

Please keep all responses to Forum posts on the Forum so that others may benefit.

Please DO NOT PM me for technical advice. My time is precious, and you will probably receive a faster response on the Forum anyway.

Check us out on Facebook! Please "like" our page!

Duh -oh, of course. Thanks Andy!

Hi tleighbell

The following are not my pictures, but hope it helps.

Phil

Hi Phil,

If you type DMR-Japan into the search bar on you tube, you will see their home page. If you click on videos, you will see various videos on their products including the wide servo pulley you are enquiring about.

There are also other Japanese videos on that specific pulley although the text/language in the videos is Japanese. Perhaps there is a way of uploading the video to a translation app so that you can understand the text in the video.

Sami

Hi Sami

Many thanks for the heads up on that much appreciated.
Phil

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.

philup_7@hotmail.com wrote:
Will be interested on any views on this (please be kind lol).

You really don't know us well at all, do you?! 🤣🤣🤣

Seriously though, thank you for the follow-up. You can't even begin to imagine how many "has anyone done/tried/fitted this, and how do I go about it?" posts we've seen over the last 27 years, that have never been followed through. We'd love to try it all first and report the findings, but those days a largely passed now, so need good people like yourself to carry the mantle forward. I've not been on the forum for a little while, as I'm busy writing the new site, but it's sincerely sppreciated.

Keep us posted on how it goes please.

I am considering a "blog" type section on the new site for authorised members where articles just like this can be uploaded with photos and maybe even embedded videos. (The forum runs on old software, and is pretty heavily customised, so it's difficult to add more modern features like embedded video, which I think is dragging us down a bit.) I'd be up for colaboration with any such "blog" post in the future, whereby I can 3D model & render some parts, and do 2D tech diagrams (I use Solidworks for work) for a (no offence) more polished final product.
_________________
Andy.
NSR-WORLD.COM

Please keep all responses to Forum posts on the Forum so that others may benefit.

Please DO NOT PM me for technical advice. My time is precious, and you will probably receive a faster response on the Forum anyway.

Check us out on Facebook! Please "like" our page!

Hi Andy

Will post any follow ups on progress etc no problem.

The Blog section sounds interesting especially being able to add Videos, as would like to have added some Videos on the operation of slipping clutch on the Servo Pulley, although saying that, Sami1 on the forum provided a good pointer to DMR-JAPAN You Tube Site.
The link below is a link is just one:
https://www.youtube.com/watch?v=2eYq-GB058E

Sounds like you are extremely busy.

Regards

phil

Not sure if busy's the word! I really must pull my finger out on publishing the new site though. The problem is I am never satisfied with how it looks.

A big addition to the site is an HRC NSR250 history (with some NSR500 stuff thrown in for good measure too), and how the NSR250R is intertwined with them both, but I want it to be absolutely spot-on and the ultimate reference resource. It's taken about 3 years so far to bring all the information together, track down old photos, remaster many of them, and also create new images where needed. If I said the HRC history is only 5 pages, you'd probably say "three years???" and laugh, but so far, off the top of my head, that covers about 24 bikes! I've shown previews to a couple of very well-informed Honda anoraks, and they've come back and said "Wow! I didn't know that!", so I'm pretty pleased with how it's going, even if it is slow. Given that a number of the models were pure prototypes, finding information, let alone photos, has been somewhat challenging.
_________________
Andy.
NSR-WORLD.COM

Please keep all responses to Forum posts on the Forum so that others may benefit.

Please DO NOT PM me for technical advice. My time is precious, and you will probably receive a faster response on the Forum anyway.

Check us out on Facebook! Please "like" our page!

Wow Andy that sounds one hell of a lot of work on top of what is on the Site already.

Can I ask is the PM working as I have tried to send you a PM from different Browsers and it still stays in the Outbox, although it says it has sent the message!

Phil

Yeah, PM's working fine. Sorry, just hadn't got round to opening it yet, sorry.
_________________
Andy.
NSR-WORLD.COM

Please keep all responses to Forum posts on the Forum so that others may benefit.

Please DO NOT PM me for technical advice. My time is precious, and you will probably receive a faster response on the Forum anyway.

Check us out on Facebook! Please "like" our page!

Hi
Thought I would share the following Service Manual updates and addendums that I did for my sons NSR250 MC18 R5K.

Hope they are of use to someone, but as always be glad of any feedback of things that I have done incorrectly or could be done better another way etc.

Even built a water manometer (ideas from youtube of course) for testing the Air Solenoids, which takes me a back far too many years when I used water and mercury Manometers for testing pressure devices on planes lol.

Regards

Philip