71 R5 Project - Build

[irk_miller]

What Wade said.  I've always made them myself when the market doesn't provide.  Bore out the inside of your 520 sprocket, machine the outside of the 530 or 525 sprocket, machine a flange for alignment or make a jig, then weld them up.  If you don't have the tooling for hardened steel, you'll need to anneal the sprocket first, then harden them back up, if you care.

[71R5JPAR]

Fired up the 3D printer to aid in mockup. Printed a brake side spacer to get wheel alignment. Then printed a 10mm offset sprocket. Then a simplified sprocket carrier and cush. Looks as though the duke wheels are going to work out just fine. Just need to source the 10mm offset sprocket and machine the hub.

[teazer]

https://www.fastfromthepast.com/99-0002

[71R5JPAR]

Output shaft spline is different. As others have mentioned, and I also saw on another build, buying a 530 sprocket from another bike and reducing the width to 520 size should work dandy

[71R5JPAR]

Custom 10mm offset sprocket has finally been delivered! Now I can finalize my tire&chain alignment and send out the rear hub to be machined.

Hagon shocks added also.

Ended up grabbing a set of Moto Carrera GP single side outlet pipes. Previous owner purchased them for a 76 RD400 project that never ended up happening. Was told they'd fit up to an R5 with slight modifications. I still need to modify the mounting location to get them tucked under the bike better. Can anyone fill me in on information about these pipes? I have yet to stumble upon photos of Moto Carrera single side outlet pipes on RD's that look like these (silencers pointing upwards).

[SoCal250]

Doug made some Moto Carrera Millennium GP right-exit pipes back around 2000-2005. They were basically the same as his regular Millennium GP pipes (which were originally designed by Tommy Crawford) except the left pipe crossed over so both silencers mounted on the right. He used them on his Del Mar Specials and they were available for the 350 and 400. See photos below. The one with the chrome pipes was parked in his No. Hollywood store for a few years.

The pipes in your photo appear to have longer headtubes for some reason and the tips are more upturned than I remember. The silencers look different as well.  It might be partly the photo but something looks off.  If your headtubes were shortened at the cylinder, it would tuck the pipes up better under the front of the frame and engine, and at the same time it would rotate the silencers downward a little.  Are the pipes seated into the flanges at the cylinders?

Garrett from GRA restarted production on MC pipes a few years back for a short period, but I don't believe he made any right-side-exit versions. His version used a different flange that utilized an O-ring.

[71R5JPAR]

Doug made some Moto Carrera Millennium GP right-exit pipes back around 2000-2005. They were basically the same as his regular Millennium GP pipes (which were originally designed by Tommy Crawford) except the left pipe crossed over so both silencers mounted on the right. He used them on his Del Mar Specials and they were available for the 350 and 400. See photos below. The one with the chrome pipes was parked in his No. Hollywood store for a few years.

The pipes in your photo appear to have longer headtubes for some reason and the tips are more upturned than I remember. The silencers look different as well.  It might be partly the photo but something looks off.  If your headtubes were shortened at the cylinder, it would tuck the pipes up better under the front of the frame and engine, and at the same time it would rotate the silencers downward a little.  Are the pipes seated into the flanges at the cylinders?

Garrett from GRA restarted production on MC pipes a few years back for a short period, but I don't believe he made any right-side-exit versions. His version used a different flange that utilized an O-ring.

You are right about the headtube length also. I agree something looks off but I haven't found much photos of these pipes online. Previous owner had paperwork from fast2stroke@yahoo.com with a physical address of 4001 Summitview Ave. Yakima Washington. Almost wondering if these were really meant for a different motorcycle model. Flanges bolt up to the cylinders just fine. Rear mounting points is about 1" off which is to be expected if they were for a RD400. Just headtube length and silencer position does not seem right.

[SoCal250]

You are right about the headtube length also. I agree something looks off but I haven't found much photos of these pipes online. Previous owner had paperwork from fast2stroke@yahoo.com with a physical address of 4001 Summitview Ave. Yakima Washington. Almost wondering if these were really meant for a different motorcycle model. Flanges bolt up to the cylinders just fine. Rear mounting points is about 1" off which is to be expected if they were for a RD400. Just headtube length and silencer position does not seem right.

That email & physical address belong to Doug Johnson after he closed his So Cal shop and moved to WA to be near family (around 2009?) due to health reasons. Doug is/was Moto Carrera, the company he founded in the late 80's.
As I recall, he had contracted someone to make some more of his pipes after he moved back to WA, and some of them had some QC issues (pieces not welded together in correct clocking so convergent & stinger were out of place). It's possible these were constructed during that time. AFAIK Doug only made the GP rt-exit pipes for R5, RD250/350, & RD400. Possibly also for the RZ but I don't remember.

[71R5JPAR]

If I've seen correctly, Doug has since past. Is Garrett reachable? I believe I've read that he puchased the old tooling for these pipes. Maybe Garrett would have some information.

[m in sc]

garret is actually on this forum, but I think the pipe thing went to the wayside?  yeah the headpipes were always crazy long on those

[AAAltered]

Doug indeed passed away in 2022...

https://obituaries.yakimaherald.com/obituary/doug-johnson-1086749410