Two Stroke Racelab

Repaired Error2 on PgmIV.

2026-05-01T21:31:00.006+03:00

No more Error2 and Error3 for James PGMIV but what I really enjoyed was getting his memory card to a much better looking condition even though he didn't ask. There was a dissolved sticker on top, but it did feel like the stock sticker was beneath. Maybe it was just a blinky sticker and I hope it was not a JHA. Who knows, it was very stubborn but nothing that some acetone and elbow grease can't solve. Just be gentle and work quick or else acetone will eventually attack the plastic.

Nsr250 MC28 stock memory card converted to HRC 030.

2026-03-21T13:57:00.002+02:00

Repair - Programming for Nsr250 Mc28 PGMIV units and memory cards.

2026-03-06T13:21:00.023+02:00

Regarding the PGMIV units, I can provide the following services.

Memory card & PGMIV EEPROM Programming :

1) Memory card cloning so you can have an extra key for your bike.

2) Memory card matching to any PGMIV unit.

A memory card is programmed from the factory with a unique serial code and only works with a specific PGM unit. I can reprogram any card to work on your own PGM unit.

3) Conversion of a stock memory card to HRC specs and vice versa, including altering ignition maps, e.g. converting an HRC 010 card to 030 specs.

For using an HRC card, the stock wiring loom needs to be modified.

A reversible wiring loom modification is available in the link below :

Mc28 Wiring Loom modification for using an HRC card.

4) Mileage alteration.

This is a service that I’m reluctant to provide, but I'll make exceptions in certain circumstances, e.g lost data due to malfunction.

5) Matching a PGMIV to a second PGMIV unit.

In case you have a spare PGMIV unit, it can be used as a backup and work with all of your existing cards. After reprogramming, all available memory cards will work — unlock both PGM units. Of course, if only a single memory card is available, it can be used to unlock both PGMIV units. This is a highly skilled and laborious service, but the second PGM unit will be ready to plug and play at any time with the same memory card(s) you currently use. If the spare PGM unit already comes with a card or two, they can be duplicated to work as extra keys or reprogrammed to HRC specs or whatever you may need.

PGM4 ECU Repair :

PGMIV units, like all other ECU units, can have ignition, Rc Valve, Rev counter issues etc. I can fix most PGM issues.

PS. Of course, I still provide PGM repairs for Nsr250 Mc18 MK2, MC21 and all Rs250 bikes from NF5 up to NXA, including NSR500. A one-stop repair shop for PGM units.

PGMIV internal reprogramming.

2026-01-25T16:04:00.005+02:00

I recently bought a PGM4 unit and started experimenting from day one, performing the strangest ideas.

One of the many issues that I had with memory cards was retrieving the password from PGM4 units that had no cards at all, altering mileage, etc. Even though I solved these issues, I still wasn't satisfied.

I thought that if it's possible to match a memory card to a PGM4 unit, why not go a bit more advanced and match the PGM to the memory card? So let's assume that I have two PGM4 units with only a single card; why not use it to unlock both? If I have a PGM4 unit with 3 memory cards and a second spare PGM4 unit with 2 cards, why not use all 5 cards on both units?

And my assumption was correct; memory card matching is not the only option, but PGM4 matching is also possible. I'm not sure if this was done in the past or if it's helpful, but I was intrigued to try anyway.

For example, the PGM4 unit that I bought had no cards at all. But I also have here a second PGM4 unit that belongs to Tom (UK) and is in perfect working order, and I didn't want to mess with it.

So, I did the opposite job. I internally matched my PGM4 to Tom's unit. This means that now Tom's memory cards also unlock my own PGM4 unit. Neat and easily reversible!

While I was there, I also altered mileage.

TRIP : current year
TOTAL : current date (sorry, not enough digits on the LCD, so let's assume it says 25/1/26) 🙂

Have fun.
Nick

Nsr250 Mc28 - HRC Memory Card, Loading new ignition map

2025-12-10T22:56:00.002+02:00

Here is a photo of an HRC memory card loading data to the main EEPROM of the PGMIV. Loading of the ignition map and data takes about half a minute, and it only happens once. After that, the PGM4 unit remembers the HRC card and is ready to run immediately.

There is an exception to this, and that is when you're using more than one HRC card. In this case, data loading to the PGMIV happens each time you change the HRC card. e.g., changing from P - 010 to P - 030 ignition map.

PGMIV will only remember the last HRC card that you used.

This never happens with the stock memory card as it's hardcoded to the PGM unit and always starts immediately.

Nsr250 Memory Card Reprogramming.

2025-12-03T14:53:00.012+02:00

Recently matched standard memory card.
The owner only had an HRC card and was missing the standard card. Along with his PGM4 unit, he provided an orphan card that I matched to work on his bike.

A memory card does not have to be for a specific use.
So, in case of necessity, if the correct card cannot be sourced, any memory card will do. e,g a standard card can be converted to HRC P-010 specs and of course, vice versa.

MC28 Memory Card ...Back from the Dead.

2025-11-27T19:29:00.005+02:00

Some people might spot something out of place in one of the photos and this would be a highly damaged Nsr250 Mc28 stock memory card running the HRC 030 ignition curve!

But let me get you back to the beginning.

More than ten years ago, my good friend Thanassis bought a few MC28 parts from a bike that had been involved in a major crash. The dash was totally destroyed, the memory card was broken in several places and the PGM4 is nowhere to be seen since the crash.

So, I had to...
a) work on the memory card and see if it can be repaired???!!!
b) If yes, is it possible to match it to work on another PgmIV unit?
c) If yes, can it also be reprogrammed to HRC specs?

a) The card had an issue with a broken PCB trace for the antenna that the card features to communicate with the main EEPROM, a couple of physically damaged capacitors and a transistor.
Parts were renewed, but I still couldn't tell if the card works or not, so it was kept at the corner of the desk for several weeks.

b) So, the next phase was to find the chance to match the card to another PGM4 unit.
Marv(UK) entrusted me with his PGM4 and two cards, one HRC card and one orphan card that he needed to be reprogrammed and matched to his bike.

So, I thought that I would finally have the opportunity to duplicate the code on “Thanassis” memory card and see if it works.
First time that I plugged it in …and to my great satisfaction, it’s back from the dead!

c) I should have called it a day, but I couldn't resist... why should you need an HRC card if you can reprogram a stock card with the HRC code in it?

Let's remove the eeprom chip once again ...and eureka!!! :)

P.S I also did some work on the PCB for the LCD and it should now work, but I'm unable to find a LCD screen to try it out. If anyone knows a source, please let me know. I hope I don't need to find a solution here, either.

Mugen PGM for Crm250 AR, now in full working order.

2025-11-23T16:58:00.000+02:00

After 3 months of waiting time, the repair shop said that the Mugen AR PGM is dead and can't be fixed. I received the unit from James(UK) last week and it's already repaired and ready for posting back.

PGM4 units, next in line.

P.s Who would have thought that after so much love and experience on 2stroke engines, I would end up mostly doing electronic stuff. Regarding 2stroke engines, electronics is my weakest and less understood subject!? People ask why I don't still make expansion chambers, porting and lathe work etc. but it's not easy for a one man show and being based in Greece one does not only has to excel in a specific matter but instead provide something that no one else can, there's no other way around.

Rd500 Restoration

2025-11-10T14:28:00.001+02:00

David(AU) and his journey on restoring a RD500 bike.

Thanks for your kind words Dave.

Nsr250 PgmIV

2025-09-24T18:24:00.013+03:00

Lazy morning, torturing a Nsr250 PgmIV, listening to Mogwai.

PgmIV, Back to Life.

2025-09-23T16:24:00.005+03:00

No more ignition issues for Tom's PGM4 unit.

I really enjoyed this repair as I learned tons of stuff about the Mc28 PGMIV unit.

I can certainly help if a PgmIV needs a repair job.

I'm currently working on memory card reprogramming as well. Have fun. Nick

Nsr250 Mc28 Wiring Loom modification for HRC card.

2025-09-13T16:37:00.014+03:00

Quick and dirty modification that allows the use of HRC cards on a stock MC28 wiring loom. Modification is easily reversible by removing the jumpers that were salvaged from a highly damaged Mc21 wiring loom.

For references I've used Matt Patterson's article :

MC28 NSR250 WIRE SPLICE

and also Eric Gietl's similar modification :

nsr-world.com - MC28 no cut wire splice

Top jumper shorts Oil switch (Green/ Pink) to Ground.
Bottom jumper shorts Side Stand switch (Green/ White) and also GPS - Neutral switch (Light Green/ Red) to Ground.

P.s According to my findings so far, not all three grounding points are needed though I don't have a HRC card to try at the moment and I just started researching PGMIV units so I might be wrong. Have fun. Nick

Nsr250 Mc28 PGMIV, under the knife.

2025-09-07T16:31:00.005+03:00

It must be about 12 years since the last time that I worked on a PGM4 unit. Back then I repaired a few but I had my own Mc28 bike as to try them out. At some point I had to sell the bike and as demand for Pgm4 repairs was very little, I omitted to keep proper notes of my work and the bike.

Tom(UK) insisted that I should work on his damaged PGM4 unit and entrusted me with all the bits that I need as to do proper research on them, including a wiring loom, stock card, clocks etc.

To be honest, after so many years working on PGM units from Crm250 up to Nsr500 units, repairing the ignition issues on Tom’s unit seems much less daunting than I thought.

Hopefully, I will soon be able to repair PGM4 units as well. Stay tuned. Nick

P.S I would also like to say big thank you to my good friend @Thanassis Karabellas for his continuous support and for providing me with a couple more Mc28 parts that I need.

OZZY

2025-07-25T18:23:00.003+03:00

This blog is now 15 years old!

2025-07-06T12:57:00.001+03:00

Time flies while you ride a 2stroke and this blog is now 15 years old.
Have fun and keep the two strokes alive! Nick

RD500 YPVS control units, repaired and ready to plug & ride.

2025-06-24T13:30:00.004+03:00

Two more RD500 bikes will once again ride smoothly soon.
Many thanks to Jean(CA) for the photo.

Crm250 AR PGM units

2025-06-04T13:24:00.001+03:00

Rc Valve issues on AR PGM units are not easy to repair but not impossible.
Two more units ready to get back to Karl(UK) and Sunny(MT).

2t-Racelab Stickers #15

2025-01-10T18:17:00.003+02:00

Many thanks to Steve(UK) for the photo.

RZ500 in the background...

Happy New Year to all!

2025-01-04T18:29:00.000+02:00

Happy New Year to all.

First post for 2025 with photos from Sam's(UK) Crm250.

NSR250 MC21 @ iconic motorbike auctions

2024-12-19T09:19:00.004+02:00

Click in the link to read full story :

iconicmotorbikeauctions.com/auction/1990-honda-nsr250-mc21-3/

Battery Eliminator

2024-12-14T12:13:00.001+02:00

James(UK) asked for a Battery Eliminator for his Crm250 bike and even though I've stopped making them a couple years back, I thought of making another bunch.

If you need one please message me for orders.

P.S The BEs will come with ring terminals for M6 screws. If you need another type of connectors please send me details and I'll do it for you. Thanks. Nick

2t-Racelab Stickers #14

2024-12-08T11:23:00.002+02:00

Sam(UK) had an issue with the RC Valve section of his Crm250 AR PGM unit but it's now a thing of the past.

Thanks for the photo Sam!

2t-Racelab Stickers #13

2024-12-08T11:21:00.003+02:00

Many thanks to Marc Tansey for the photos of his Nsr250 Mc21. Cheers. Nick

2t-Racelab Stickers #12

2024-12-08T11:17:00.003+02:00

Many thanks to Paul(USA) for the photos of his awesome Nsr250.

BRC Racing

2024-12-08T11:13:00.001+02:00

Many thanks to BRC Racing for trusting my services on PGM repairs. I cannot express how grateful I feel when dealing with people that make great products - services and keep the 2Strokes alive. Nick

BRC Racing - Facebook