2002 NSR 125 JC22 Full Teardown & Rebuild [Updated 12/04

[BenR]

Great project nice attention to detail.

[anthony_r6]

I miss my NSR. Your bike looks absolutely perfect. Can't wait to see the finished article.
____________________
Ted : "Maybe he's agoraphobic."
Dougal : "Jack scared of fighting? I don't think so, Ted."

[ripzay]

Hi all, I can only apologise for the lack of updates on this project, but here's an update.

The bike is going in for its MOT in the next week, and is complete bar putting clearcoat over the decals...


I didnt get any photos while we were doing the fairings, but there was a LOT of plastic welding, some fairings were missing chunks which had to be fabricated from scratch using a soldering iron and some sacrificial ABS plastic..

Painting was done at home with a HVLP gun and 2 pack paint.

3 coats of primer, 3 coats of black, 1 coat of clear, then decals, (and another shed load of clear still to go on over the top of the decals.

the paint has a bit of orange peel (expected given they were painted at home, but overall is pretty dust free, and once the remainder of the clearcoating is done, a careful flat back with wet & dry, then G3 & G10 will have it looking much better.

Apologies for the potato photos - no camera, got to use phone :/.

https://dl.dropboxusercontent.com/u/183506/bikes/NSR125/Fairings%20Painted.jpg

https://dl.dropboxusercontent.com/u/183506/bikes/NSR125/Fairings%20Paint%20Finish.jpg

https://dl.dropboxusercontent.com/u/183506/bikes/NSR125/Fairings%20On.jpg

https://dl.dropboxusercontent.com/u/183506/bikes/NSR125/Decals.jpg
____________________
Current: 2005 KTM SuperDuke 990
Previous: 1996 Suzuki Bandit 600
Previous: 1994 Suzuki GSX-R 400

[ripzay]

And for completion....

Before:

https://dl.dropboxusercontent.com/u/183506/bikes/NSR125/Teardown%202.jpg

After:

https://dl.dropboxusercontent.com/u/183506/bikes/NSR125/Done%201.jpg
____________________
Current: 2005 KTM SuperDuke 990
Previous: 1996 Suzuki Bandit 600
Previous: 1994 Suzuki GSX-R 400

[Just_James]

Great project and some really nice work there

Absolutely transformed that bike and given it many more years of service!
____________________
Current Bikes / Projects: 1999 Rieju RS1 50
Previous bikes - 1986 DT125R (field bike), 1989 KX250, 1980 KX420 (with 500cc big bore), 1992 YZ250, 1988 KX500, 1989 XR250R, 1988 VFR400R NC24, 1999 Cagiva Mito 125, 2008 Rieju RS2 50 , 1993 Honda NSR 125

[waffles]

Nice tidyup thread, was it cosmetic stuff and electricals that you did or did the engine get some TLC too?
____________________
Theory test - 19/8/09, CBT - 11/10/09, MOD 1 - 16/8/10, MOD 2 - 27/10/10
Past rides Yamaha XT125X, Triumph TT600, Honda XR250
Current rides Suzuki GSXR 600, Honda MSX125

[ripzay]

[Mark65]

Awesome job there, your girl is a keeper
____________________
07 Yamaha YBR125, 07 Honda CG125 , 15 CBR300R (Chocolate Crank, Deaded), 16 CB500FA, 19 Honda Forza 300, 70 Suzuki SV650