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

[ripzay]

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

[ripzay]

I'll continue to add updates from here on - don't expect the rest to be this big though! we don't get much time to work on the bike while we are both at work - conflicting timetables!

Just as a bit of background:

My other half hasn't ridden a bike since we met (6 years ago), she did her cbt and then university got in the way and she never rode a bike again.

The NSR is proving to be a great way of teaching her everything she would ever need to know about bikes, how they work, and how to fix them if they break - and above all we are both really enjoying doing the project together.

She turns 25 in October and we're hoping to have the bike Taxed and Tested and ready to ride for her birthday, this gives her the insentive to go and get her licence.

I've also learnt an important lesson out of all this - she doesnt mind motorbikes in bits in the kitchen!

TLDR: fun fun!
____________________
Current: 2005 KTM SuperDuke 990
Previous: 1996 Suzuki Bandit 600
Previous: 1994 Suzuki GSX-R 400

[i.p.phrealy]

[stevo as b4]

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?

[ripzay]

[sabian92]

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.

[ripzay]

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

[delsol]

mispost

[delsol]

Well impressed with your project,

Sleeping bag deserves explanation.

[ripzay]

Hah.. Sleeping bag was to stop the frame / swing arm / forum lowers fresh paint getting scratched before we got it on the paddock stands.. Perfect length and shape for a motorcycle...

Improvisation.
____________________
Current: 2005 KTM SuperDuke 990
Previous: 1996 Suzuki Bandit 600
Previous: 1994 Suzuki GSX-R 400

[Teflon-Mike]

Cant see pictures. Can every-one else?
____________________
My Webby'Tef's-tQ, loads of stuff about my bikes, my Land-Rovers, and the stuff I do with them!
Current Bikes:'Honda VF1000F' ;'CB750F2N' ;'CB125TD ( 6 3 of em!)'; 'Montesa Cota 248'. Learner FAQ's:= 'U want to Ride a Motorbike! Where Do U start?'

[ripzay]

Weird, work fine here on all my devices - don't show up when not signed in to the forums, just get links then..
____________________
Current: 2005 KTM SuperDuke 990
Previous: 1996 Suzuki Bandit 600
Previous: 1994 Suzuki GSX-R 400

[ripzay]

Bit of progress this weekend - We spent saturday at the british supermoto championship at three sisters in wigan, then sunday morning babysitting so we only did one afternoon...

• Steering Head Bearings Swapped
  
• Clipons fitted
  
• Throttle fitted
  
• Switchgear fitted
  
• Frame inserts stuck back on
  
• Painted some brackets and fittings - The 'black' anodized coating done by honda from the factory on lots of steel parts has gone a horrible green colour with age.
  
• Painted the exhaust with high-temp black lacquer
  
• Wheels on
  

The wheels will be coming off again to be blasted and powder coated

https://dl.dropboxusercontent.com/u/183506/Bikes/NSR125/Bars%20%26%20Wheels%201.jpg

https://dl.dropboxusercontent.com/u/183506/Bikes/NSR125/Bars%20%26%20Wheels%202.jpg

Next up is getting the front fairing / clock / headlight bracket cleaned up and painted (similar job to the rear subframe)

We have been hunting for a cover for the RC Valve pulley for this bike for the last 6 months with zero success, bought a couple off ebay that didnt fit and discovered that there are two different barrels available for this engine and therefore 2 different RC valve cover shapes, one is easy to get hold of - the other is not!

So I sent a 3D model over to a friend of mine and had him print one - which will be put in the post tomorrow!

https://dl.dropboxusercontent.com/u/183506/Bikes/NSR125/Print-Dimensions-1.png

https://dl.dropboxusercontent.com/u/183506/Bikes/NSR125/RC%20Valve%20Cover%20-%203D%20Print.jpg

Also added a couple more teardown pics to the OP
____________________
Current: 2005 KTM SuperDuke 990
Previous: 1996 Suzuki Bandit 600
Previous: 1994 Suzuki GSX-R 400

[_Troy_]

Dude, marry her.
____________________
Current bike: ZX6R J1
Previous bikes: CLR 125 | GS500 | ZX6R G2 | SV650

[skatefreak]

[nowhere.elysium]

[ripzay]

he's been having trouble with the printer (he has 2, one is currently in bits, the other has things that need replacing), but he's also in canada and is currently battling forest fires so the quality of my print wasn't at the forefront of his priorities.

Will see how it looks when it arrives - regardless it's going to be better than the cover that was on the bike when we got it... (there wasn't one!)
____________________
Current: 2005 KTM SuperDuke 990
Previous: 1996 Suzuki Bandit 600
Previous: 1994 Suzuki GSX-R 400

[blueglue]

Good stuff

[BenR]

[nowhere.elysium]

OK, but I have multiple 3D printers, and I'm in the UK, as opposed to Canada. You have but to ask.
____________________
'10 SV650SF, '83 GS650GT (it lives!), Questionable DIY dash project, 3D Printer project, Lasercutter project

[ripzay]

Can send you the stl file.. Estimate on the cost? The one that is on its way is PLA.. If you can print ABS that would be better?

Cheers.
____________________
Current: 2005 KTM SuperDuke 990
Previous: 1996 Suzuki Bandit 600
Previous: 1994 Suzuki GSX-R 400

[ripzay]

Few small updates..

RC Valve Cover

Cover arrived from my friend in canada, we did some clean up on it and painted it (and the part it mates to)....

https://dl.dropboxusercontent.com/u/183506/Bikes/NSR125/RC%20Valve%20Cover%203D%20Print%20Fit%201.jpg

https://dl.dropboxusercontent.com/u/183506/Bikes/NSR125/RC%20Valve%20Cover%203D%20Print%20Fit%202.jpg

https://dl.dropboxusercontent.com/u/183506/Bikes/NSR125/RC%20Valve%20Cover%203D%20Print%20Fit%203.jpg

... Then fitted it ...

https://dl.dropboxusercontent.com/u/183506/Bikes/NSR125/RC%20Valve%20Cover%20Fitted.jpg

Rearsets, footpegs & Pillion Handle

Cleaned up, filled some small scratches, painted and fitted the rearsets and pillion handle

https://dl.dropboxusercontent.com/u/183506/Bikes/NSR125/Rearsets%20Pillion%20Handle%20Paint.jpg

https://dl.dropboxusercontent.com/u/183506/Bikes/NSR125/Rearset%20Left.jpg

https://dl.dropboxusercontent.com/u/183506/Bikes/NSR125/Rearset%20Right.jpg

.. still need to sort the heel plates out.

Clock Subframe & Clocks

Cleaned, de-rusted, painted and fitted the clock subframe and connected up some of the wiring...

The Trip odometer on the clocks was broken, so we tore the clocks apart and fixed it - the spindle that the odometer dials sat on had come out of its hole and was just hanging in the clock surround. the normal odometer was fine, and none of it showed any signs of tampering!

https://dl.dropboxusercontent.com/u/183506/Bikes/NSR125/Clocks%20And%20Subframe%201.jpg

https://dl.dropboxusercontent.com/u/183506/Bikes/NSR125/Clocks%20And%20Subframe%202.jpg

Where we are at right now...

https://dl.dropboxusercontent.com/u/183506/Bikes/NSR125/Second%20Stage%20Build.jpg

Battery is in and on the optimate ready for testing some of the electrics.. the battery is new but has been stood for a couple of years (probably with no charge in it) - we'll see if it can hold charge...
____________________
Current: 2005 KTM SuperDuke 990
Previous: 1996 Suzuki Bandit 600
Previous: 1994 Suzuki GSX-R 400

[ripzay]

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

[paddlesat16]

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.

[colette1989]

A few bits done today.

- exhaust on
- side stand on
- brake calipers on

Not all that much done this weekend because I was too busy doing this...

https://dl.dropboxusercontent.com/u/183506/Bikes/NSR125/john.jpg