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ripzay |
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ripzay Nitrous Nuisance
Joined: 01 Dec 2008 Karma :
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Posted: 23:13 - 13 Jul 2014 Post subject: 2002 NSR 125 JC22 Full Teardown & Rebuild [Updated 12/04 |
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Hi All
Already a fair way through this project but thought i'd post a 'log' of sorts and share.
This isn't my project, it's my girlfriends - i'm just here to teach! (and post stuff on forums)
The bike is a 2002 nsr 125 r, bought off my brother for £300, it had spent the last 3 years off the road and was in need of a lot of TLC:
- lots of rust on anything that's steel
- Most of the fairings have damage on them
- Some broken parts
- Some missing parts
- Prior to being stood for 3 years it was used in all weather and never really looked after - it's filthy
We've been working on it on and off for a month or two now.
Some pics of the teardown:
https://dl.dropboxusercontent.com/u/183506/Bikes/NSR125/Teardown%201.jpg
https://dl.dropboxusercontent.com/u/183506/Bikes/NSR125/Teardown%202.jpg
https://dl.dropboxusercontent.com/u/183506/Bikes/NSR125/Teardown%203.jpg
https://dl.dropboxusercontent.com/u/183506/Bikes/NSR125/Teardown%204.jpg
https://dl.dropboxusercontent.com/u/183506/Bikes/NSR125/Teardown%205.jpg
Engine Clean
Toothbrush, cotton buds for the 'hard to get to' areas and petrol, then a liberal wipedown with WD40.
https://dl.dropboxusercontent.com/u/183506/Bikes/NSR125/Engine%20Before.jpg
https://dl.dropboxusercontent.com/u/183506/Bikes/NSR125/Engine%20During.jpg
https://dl.dropboxusercontent.com/u/183506/Bikes/NSR125/Engine%20After.jpg
The frame is in good order (yay for alcast) and just needs a deep clean (inside is similar to the engine before pic).
The rear subframe is just showing minor signs of surface rust so that will be stripped, rust ground off, treated and painted.
The swing arm and rear shock were beyond recovery with piles of rust coming out of the end of the swingarm, and still some rattling around inside that has no exit route! so she has bought a second hand one from ebay that's in decent nick and has undergone a clean and then paint.
We took the week off work as a sort of 'holiday' and have spent Wednesday to Sunday working on the bike and have made great progress:
Weds 9th
Lots of cleaning of parts, removal / treatment of rust, and primer...
https://dl.dropboxusercontent.com/u/183506/Bikes/NSR125/Subframe%20Before%20Paint.jpg
https://dl.dropboxusercontent.com/u/183506/Bikes/NSR125/Parts%20Primer.jpg
Thurs 10th
Get some paint on it!
Note the expertly made (by me) frame to hold the frame while she paints...
https://dl.dropboxusercontent.com/u/183506/Bikes/NSR125/Parts%20Paint.jpg
https://dl.dropboxusercontent.com/u/183506/Bikes/NSR125/Frame%20Paint.jpg
https://dl.dropboxusercontent.com/u/183506/Bikes/NSR125/Parts%20Paint.jpg
[img]https://dl.dropboxusercontent.com/u/183506/Bikes/NSR125/Parts%20Jigsaw.jpg[/img]
Fri 11th
Was spent lacquering everything ready for the build of the rolling frame... no pictures here...
Sat 12th
Wiring Loom - Completely took the loom apart, remove the horrible electrical tape and hardened with age tubing that the loom is encased with from the factory and re-sheathed it in beautiful braiding, joining with adhesive lined heat shrink..
https://dl.dropboxusercontent.com/u/183506/Bikes/NSR125/Wiring%20Loom%20Before.jpg
https://dl.dropboxusercontent.com/u/183506/Bikes/NSR125/Wiring%20Loom%20Braiding.jpg
Chain Adjusters & Bolts
The chain adjusters were a mess with rust: got it all off the accessible bits, and treated the inaccessible stuff with kurust:
https://dl.dropboxusercontent.com/u/183506/Bikes/NSR125/Chain%20Adjusters%20-%20De-Rust.jpg
https://dl.dropboxusercontent.com/u/183506/Bikes/NSR125/Bolts%20Derust.jpg
The Build begins
https://dl.dropboxusercontent.com/u/183506/Bikes/NSR125/Build%201.jpg
Forks in:
At this point we discovered that the steering head bearings need replacing (notchy and pretty stiff) - Couldnt get new bearings from local places so they are ordered.
https://dl.dropboxusercontent.com/u/183506/Bikes/NSR125/Build%202.jpg
Too eager - Polishing bits already.....
https://dl.dropboxusercontent.com/u/183506/Bikes/NSR125/Build%203%20Polishing%20Already.jpg
Sunday 13th:
Engine, Wiring Loom, Power Valve Servo etc. In:
https://dl.dropboxusercontent.com/u/183506/Bikes/NSR125/Build%204%20Engine%20In.jpg
https://dl.dropboxusercontent.com/u/183506/Bikes/NSR125/Build%207%20Engine%20In.jpg
https://dl.dropboxusercontent.com/u/183506/Bikes/NSR125/Build%206%20Engine%20In.jpg ____________________ Current: 2005 KTM SuperDuke 990
Previous: 1996 Suzuki Bandit 600
Previous: 1994 Suzuki GSX-R 400
Last edited by ripzay on 21:06 - 12 Apr 2015; edited 15 times in total |
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ripzay |
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ripzay Nitrous Nuisance
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i.p.phrealy |
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i.p.phrealy World Chat Champion
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stevo as b4 |
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stevo as b4 World Chat Champion
Joined: 17 Jul 2003 Karma :
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Posted: 23:39 - 13 Jul 2014 Post subject: |
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Well it looks like your both doing a great job on it so far!
It should be very smart indeed when finished?
Did the engine need any work bar cleaning? I'd have been tempted to at least inspect the top end, unless you knew it was either a recent re-build or a sweet runner? |
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ripzay |
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ripzay Nitrous Nuisance
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sabian92 |
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sabian92 World Chat Champion
Joined: 21 Oct 2012 Karma :
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Posted: 18:54 - 14 Jul 2014 Post subject: |
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Awesome I love these NSRs.
Make sure she gets a licence before she rides it though, you can't ride it on a CBT unless it's restricted to under 14.6HP. |
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ripzay |
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ripzay Nitrous Nuisance
Joined: 01 Dec 2008 Karma :
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Posted: 21:36 - 14 Jul 2014 Post subject: |
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Added some more pictures to the OP:
- Some from when we were taking the bike apart
- Wiring loom before and after
- More Post-Build pics
- Other random pics dotted around the OP
____________________ Current: 2005 KTM SuperDuke 990
Previous: 1996 Suzuki Bandit 600
Previous: 1994 Suzuki GSX-R 400 |
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delsol |
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delsol World Chat Champion
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delsol |
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delsol World Chat Champion
Joined: 12 Apr 2011 Karma :
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Posted: 21:54 - 14 Jul 2014 Post subject: |
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Well impressed with your project,
Sleeping bag deserves explanation.
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ripzay |
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ripzay Nitrous Nuisance
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Teflon-Mike |
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Teflon-Mike tl;dr
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ripzay |
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ripzay Nitrous Nuisance
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ripzay |
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ripzay Nitrous Nuisance
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_Troy_ |
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_Troy_ World Chat Champion
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skatefreak |
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skatefreak World Chat Champion
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nowhere.elysium |
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nowhere.elysium The Pork Lord
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ripzay |
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ripzay Nitrous Nuisance
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blueglue |
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blueglue Trackday Trickster
Joined: 10 Jun 2014 Karma :
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Posted: 14:00 - 24 Jul 2014 Post subject: |
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Good stuff |
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BenR |
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BenR World Chat Champion
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nowhere.elysium |
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nowhere.elysium The Pork Lord
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ripzay |
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ripzay Nitrous Nuisance
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ripzay |
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ripzay Nitrous Nuisance
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ripzay |
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ripzay Nitrous Nuisance
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Posted: 22:25 - 31 Jul 2014 Post subject: |
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Tiny Update.. over the last few evenings the front brake caliper has been tackled..
Strip down, clean, paint, rebuild with new seals and pads
https://dl.dropboxusercontent.com/u/183506/Bikes/NSR125/Front%20Caliper.jpg
Happy with the result, it was an absolute mess before! ____________________ Current: 2005 KTM SuperDuke 990
Previous: 1996 Suzuki Bandit 600
Previous: 1994 Suzuki GSX-R 400 |
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paddlesat16 |
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paddlesat16 Crazy Courier
Joined: 07 May 2008 Karma :
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Posted: 11:28 - 02 Aug 2014 Post subject: |
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Excellent Project ____________________ I once saw a bloke shagging a donkey.... in Saudi arabia. Theory Test Passed 26/10/09 Mod 1 Passed 26/4/10, Mod 2 Passed 7/6/10 Current Bikes Suzuki GSX1400 K5, Aprillia Pegaso 650, Suzuki DR350T. |
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colette1989 |
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colette1989 L Plate Warrior
Joined: 17 Jul 2014 Karma :
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Old Thread Alert!
The last post was made 9 years, 262 days ago. Instead of replying here, would creating a new thread be more useful? |
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