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[info on the bike:]

hey guys i need a little help here on my pilot jetting.

this is my rd400g

https://www.youtube.com/watch?v=_fpOQJUjanM

she's on her  final stages of tuning after a complete rebuild that took almost 5 years.

info on the bike:
-altitude 5250 feet
-2r9 carbs

• 27.5 pilot jet
• 150 main jat
• keyster 5j6 needle (i have the original 5j6 needles but one has lost the anodizing, had to order the closest thing which was a rebuild kit from keyster that has the 5j6 needles from yambits, but they are a little different from the original mikuni, so had to change them both.

-2r9 exhaust
-stock airbox
-squish band on 3j7 heads fixed by chuck quenzler
-crank rebuild by chuck quenzler

the bike starts first kick with the "choke" from cold.

i synched  the carbs as per the manual suggests.

set the idle at 1400ish rpm.

i have been learning about this mikuni carbs, but still learning.
i have been fiddling with the airscrew:
When i close the airscrew totally once warm the bike does not die (should it die?). and it seems to be working better at 0.5 turns out than the 1.5 out its supposed to run.
when i open the screw 3.5 turns out, there is a change and the bike seems to get worse when out, but the difference is only noticed when I give her some throttle, not idleing.
On all positions of the airscrew (0.5 , 1.5 and 3.5 turns out) the bike returns to idle in the same manner.  not faster not slower once revved. probably better when 0.5 out like the video.
in the video the airscrew is set at 0.5 turns out from fully closed which is the one i think works better.
When i quickly open the throttle, there is a little hesitation on the bike to get from 1400 rpms to 2000 rpms. what i try to say is it does not feel linear.



my main question here is following what I have read on other posts..... should i go from 27.5 pilot to a 30 pilot?

or this means i should try  a 25 pilot?

[THIS IS THE LINK ON MY PROJECT http://www.2strokeworld.net/forum/index.php?topic=71.0]

i have been restoring my rd400g for the last 5 years. finally i have it close to finish. THIS IS THE LINK ON MY PROJECT http://www.2strokeworld.net/forum/index.php?topic=71.0

i had my original side cover and cowl which I bought around 4 year ago.

Seeing the ridiculous prices this parts can reach on eBay, I decided to experiment with a fiberglass shop in replicating the original side covers and cowl on fiber glass and make them available to everybody, this are good for whoever is missing one or two or all of them, or if you want to protect your original ones like me, keep the originals stored and use this replicas for your daily driver, right now this parts and the cylinders are probably the must expensive and hard to find parts to replace on the bike. (pretty much everything is getting hard to find)

They look extremely good you can judge by the pictures, they came out on the outside just like the originals, they will need very little prep work to have them painted to your liking.

The finish is really good, the curbs are perfect just like the originals. The molds where made out of my originals, as you can see they had to be prepped in order to make the molds that's why they are grey.

Here are some pictures testing and fitting the parts, don't mind the weird color on the tank, I'll have everything painted soon with a set that I'll be keeping for myself, the originals will be kept in a vault in Switzerland in a few years they might be word a fortune if prices keep going trough the roof.

feel free to give me any feedback from what you can see.

i posted this same post on the for sale section, with pricing. wanted to post it here also because a lot more people get to see this on this section, if you want to see the pricing head over there here is the link http://www.2strokeworld.net/forum/index.php?topic=3692.0

PM me if you are interested, and post any questions you might have,.

IMG_9568 by manuel caicedo, on Flickr

IMG_9576 by manuel caicedo, on Flickr

IMG_9569 by manuel caicedo, on Flickr

IMG_9575 by manuel caicedo, on Flickr

▼Instead of making the lower tabs for the side covers in fiber which was a weak link, we came up with this solution which is a custom-made metal tab which we made on a lathe shaped like the original, this makes the piece stronger and will last as long as you don't drop the bike, they are as strong if not more than the originals.
IMG_6039 by manuel caicedo, on Flickr

▼This tab Is held by a countersunk screw from the front, this screw will be shipped loose, I advise to use blue Loctite, and fill with your preferred choice of filler, before priming and painting so it's not noticeable, also the little tiny imperfections you can see will be filled with primer or filler. those should disappear once they are  painted.
IMG_6026 by manuel caicedo, on Flickr

▼Oil tank side covers:
IMG_6025 by manuel caicedo, on Flickr

IMG_6034 by manuel caicedo, on Flickr

IMG_6033 by manuel caicedo, on Flickr

IMG_6032 by manuel caicedo, on Flickr



▼Right side cover:
IMG_6038 by manuel caicedo, on Flickr

IMG_6037 by manuel caicedo, on Flickr

IMG_6036 by manuel caicedo, on Flickr

IMG_6035 by manuel caicedo, on Flickr


▼Rear cowl: we replicated the lip under the seat with a two piece mold, and fits fine with the tool box
IMG_6031 by manuel caicedo, on Flickr

▼the spiderweb like texture on the bottom of the parts is natural for fiberglass, this can not be seen unless you remove the side covers or lift the seat. they could be also filled if you wanted to.
IMG_6028 by manuel caicedo, on Flickr

IMG_9583 by manuel caicedo, on Flickr

IMG_9582 by manuel caicedo, on Flickr

IMG_9571 by manuel caicedo, on Flickr

IMG_9570 by manuel caicedo, on Flickr

[Here is my setup:]

carb tuning is not my forte, i wish you guys could head me in the right direction.
wont know if my jetting is correct until i start the bike, but let me know if this might be ok for a street bike.

or what  should i change? or what sizes should i get to have in my hands when tuning, also what other information do you need from the bike?

Here is my setup:

rd400g: elevation 5200 feet above sea level

-stock 2r9 pipes

-stock airbox

-prox pistons.

-yz85 reeds with TSR yz85 spacers, removed material from the cylinders in order to fit them with a Dremel.

-rebuild 2r9 carbs with the dave f mod done by chuck Quenzler.
---Keyster 2.5 Needle valves
---27.5 pilot jets                                         
---5j6 needles, One if my 5j6 needles has the anodizing off in some parts of it, Chuck said i have to find a new one, I ordered a carb kit from Yambits which allegedly comes with the 5j6 needles, still waiting on them i have not had the chance to compare them. its been really hard to get a new 5j6 needle, so the yambits ones will have to do for now, might have to place both yambits ones if they turn to be slightly different from my original one.

-Squish band fixed by chuck Quenzler.

this is it....

hope any one can be a of help.

ok guys, i removed enough material off the cylinders to fit the yz85 reeds.

i got the sacer from chuck quenzler

here are some pictures, is this fine just to leave them like that?

or should i smooth the corners so as they are rounder?

i have the original 2r9 pipes and headers for my rd400g.

which is the same as the uk rd400e. but looks like a daytona.

i need to restore the pipes, or buy new aftermaket pipes.

the bike is used in the street, so no race pipes

jim lomas pipes wont fit this bike, DG i have heard are not that good.

where can i have my pipes rebuild, (remove dents and rechrome)?

where can i find good aftermarket pipes?

does anybody have a blueprint for pipes?

there used to be a thread for wanted items.

i have 2r9 carburators for my rd400g,  i had chuck quenzler, rebuild them, they are great but i still need one of the 5j6 needles.

i have not been able to find them.

can anyone help with this

DISCLAIMER: since the old forum died, with everything else in it, (good thing i saved this post on word), so i will be reposting it in the next couple of days in the same order. and try to fix any mistakes , spelling, grammar and the presentation if i see anything wrong.



INTRODUCTION
I got this rd400g in a really bad state.
got it on November 2016 and have been purchasing parts and trying to restore the bike ever since.
I will be posting the restoration, the purchase of parts and the decision making that has gone
trough everything. Hopefully you guys can correct me if I'm making mistakes,
and we can have a correct project post restoring the rd400g as I have never come across
one on the web.
I will also keep tags on the price of parts and labor, for future references.
I have decided to post the project now, since I'm almost done purchasing the most needed
parts in order to bring this beauty to its original glory.
English is my second language so sorry for any spelling and grammar mistakes in the future.
So to keep people interested here are the pictures of my 1980 rd400g. it was registered at
that time here in Colombia, don´t know if it was built on 1979 or 1980.
My guess is 1979 but I could be mistaken. Hopefully it´s 79 since I was also born on that
year and that would be cool.

yes this is the sorry state i bought it in.

Later i will post all the problems that this piece of junk had and all the mistakes i made as a rookie, but bear with me, it´s getting there








The story on this bikes is that they were used by the Colombian police force. But so far it´s been hard to get info on them locally.