1985 Honda NSR500 [NV0B]
GP500 Works Road Racer

Running the chamber layout under the engine took a lot of work.

The Comstar wheel, distinguished by its boomerang-shaped spoke plates, is unique to Honda motorcycles. They used CFRP to make the rim and spoke plate of the NV0A, but for the NV0B, they switched to aluminum for reliability. The ingenious design made it lighter than the conventional aluminum Comstar wheel. The NV0B was the last Honda GP500 road racer to use this assembled wheel. (Photo/Shinobu Matsukawa)

Development of the NV0B began in mid-October 1984, and the machine was completed in mid-February 1985. The technology cultivated in HRC's previous road racers was diverted to components such as the front and rear suspension, wheels, and brakes to build it in just four months. However, improvements and adaptations were, of course, made.

For instance, the NV0A had a bottom link rear suspension, but the NV0B had no additional space under the engine where the four exhaust chambers were to be placed, so they relocated the link system on the upper side of the swingarm base. They had used this design on the 1982 NS500 [NS2A], but there was a tendency for the two tension rods on the NS2A to be twisted, which made it difficult to operate. Therefore, they made the cross-section of the rod on the NV0B H-shaped, and instead of two rods, it was made V-shaped and integrated to increase rigidity. Also, as there was no space to place the separate reservoir tank away from the damper body like the NV0A, a new type of rear shock with the reservoir attached to the main body was developed and used.

One of the parts that characterizes the NV0B is the V-shaped radiator. The NV0A's radiator core was flat, but the V-shape creates a space behind it. Because negative pressure is generated in that space while moving, this design allows hot air to escape more quickly than a flat radiator design that does not have any space behind it, ensuring high cooling performance. The hot air passing through the radiator is exhausted from a duct on the side of the upper cowl. (Photo/Shinobu Matsukawa)

The NV0B's most challenging aspect was dealing with the four expansion chambers. Unlike the NV0A, a layout that passed over the engine was decided not to be used.

The chassis designer, Kaoru Yamamoto, said, "We made rough layouts at our desk, such as two above and two below, or two crossed in front of the cylinders. However, each had positive and negative aspects, and we finally settled on a layout with four chambers passing under the engine."

The story continues when they decide on the layout. In the case of a multi-cylinder two-stroke engine, the principle is that the specifications of the divergent section, straight section, and convergent section must be the same for each chamber. However, the NV0B engine is a V-type four-cylinder with all cylinders exhausting from the front, and the positions of the exhaust ports for the two cylinders in the front bank and the two cylinders in the rear bank are entirely different. Yet, all four chambers had to fit into the space under the engine while maintaining the exact specifications. It was a minimal space, and the goal was to secure a bike's lean angle over 60 degrees at the time.

Yamamoto and his team used their homemade tools and ingenuity to create four chambers with identical specifications intertwined like a puzzle ring. They completed the development in a short period of four months. The NV0B that was born in this way became a machine that demonstrated historic strength, winning seven of eleven World Grand Prix races with a winning rate of over 60%.

This shape resulted from trial and error in fitting four chambers with a maximum expansion diameter of 100 mm into the space under the engine while securing a sufficient bank angle. The chambers were made of iron then, and the manufacturing method was to assemble pressed parts and weld them together. (Photo/Shinobu Matsukawa)

The image is from an angle, looking up at the vehicle from the bottom left. The most visible part is the chamber of the left cylinder (no. 1) of the rear bank, and the 90-degree bent part of this was repeatedly damaged in the debut race at Daytona. (Photo/Shinobu Matsukawa)

Searching for ULF

A little before the development of the NV0B, around 1982-83, HRC conducted research on the ULF (Ultra Light Frame). As a replacement for the double cradle that had been used up until then, the search was for a new generation frame that would be light, highly rigid, fully compatible with the ever-deepening lean angle, and allow for a high degree of freedom in the layout of the engine, etc.

One of the things tried out was a twin-spar frame with CFRP (carbon fiber reinforced plastic) for the spar. They built an actual machine using the NS500's V-3 engine and components, and tests were conducted in strict secrecy. However, the rider, Takao Abe, known for his high evaluation ability, said, "This is no good," and the project was shelved.

This carbon frame is an example of ULF research and has no direct technical connection to the aluminum frames with two ribs inside used in the NV0B and other models. Kaoru Yamamoto, a frame design engineer, said, "At the time, HRC's frame builders were all thinking about different things. But the requirements were the same, so in the end, everyone thought about the same things."

The "NS500-ULF" shown in the photo was developed as a research theme to verify these two technologies, such as twin-spar frame shape and carbon material, without the direct goal of putting them into actual racing. They created this work in 1984, and the development engineer took this photo then.