Swing arm

Hi,

As the frame is done, now is the time to move to the swing arm. Previously it is using the KR150B model, but has damaged because of the sprocket housing have fallen out from the wheel. The swing arm took some serious damage, and as I have a spare swing arm at my disposal, i took it to replace the molested swing arm.

The bearing is rare as a hen's teeth! i thought looking out for a bearing was an easy task, or at least NKS Sentul would have it. It turns out the don't but id found an original swingarm bearing for it, which costs MYR90 for a piece, that's RM 180 thrown out of the window! So the next best thing is to take the bearing from my previous arm,as it still looks good.

But that is not all. After completion of painting the arm black, i found out the previous bearing is still inside, but only the outer cage. This brings the process into a screeching halt. I can't knock it out due to i don't have the correct chisel for it.

Bugger. So once again, i have to bring it to my friend's shop to grind-knock-grind-curse at it and finally it came out. So after freezing up the bearing inside the freezer, and blow torch the arm, the bearing were knocked with a light tap to put it in. Now, time to get the fork sorted out.

Weighing up

Hi,

After the frame were finished, i take some time to sort the things needs to be done. Forks, wiring, fairings, etc. And this is some the item that i measured.

Wiring only weighs 210gm ! That is not included with the plug coil yet.

the battery eliminator (capacitor) to replace the heavy battery which weighs approx. 3kg plus. However i cannot runs total-loss ignition on these.

The CDI from Phantom. It maybe changed with the IGNITECH programmable i have laying around but that is still to be decided upon how easy the programming might be.

Tapered steering bearing

Hi,

I bought the tapered steering bearing, as i have always wanted to have this. No more chasing all over the parking lot / garage for the ball bearing. Its also wont have the notch like those retards RXZ usually have when they overtighten the steering. The hunt suppose to be taking some time, and since a guy sells it on Fb, i just make the payment because it is so much faster than sourcing one myself.

This is the picture given from the seller. I think this picture is from NSR 150 RR, the SP have slightly bigger bearing according to him.

 Delivered in 1 day, this is remarkable as buying online usually takes 3 weeks to a months in these days. :(

I have installed it this morning, just before going to work. Previous bearing race was a bastid to remove. I left theses tapered one in fridge for a night, and blow gun the frame where the bearing sits for easier installation. Job;s jobbed. Next, the forks are going to have a visit. New spring, modded damper rod is in the pipeline.

Frame

Hi All,

Last week have been a productive weekend, where the Ninja 250 have finally started, but still have some minor problem that would need to be sorted but nonetheless I have done some seat time on it, and some Break-in period for the new pistons and the AFR not sorted and bla..bla...

 

I have managed to finalise the paint on the frame, where I have put 2 coats of Flat black and also Flat clear on top of it. I might need some more clear coat as the paint have been sold out at the shop. Note to self " 2 spray can for NSR frame", otherwise you might have to run out to get some more in the middle of the process.

Here is the finished frame…so glad it is flawless LOL..as compared to paint it while the engine is still on the bike. No more spot where the paint cannot reach. Next task would be painting the swing arm, as i saw 1 bike which looks great with black frame and swing arm, with white wheels.

Looks great is it?

Swingarm

Hi,

The swingarm (if you still remembered) is a mess. The sprocket carrier were thrown out due to a failure with the mechanic to alert on this simple task means the swingarm needs repair / replace.
I already have a same swing arm in hand, so using that one is a no-brainer.
However, it needs to be machined like this since i don't want to use the Uni-trak suspension on the bike.

The machine process was already done without the picture, and it only costs me RM 60.
Next task is to buy the swingarm chain adjuster end, new swingarm bearing and might need some machine to the frame due to the bad machining job done to it.

Frame

Hi All,

Sorry for the late updates, i have been struggling with work, and with the Ninja250 at nights (It is sort-of-finished now, yeay!) so i haven't got time to update.
Long story short, here's the progress so far.

 Cleaning years of road trash and grimes...was not a fun task!
Here i highlighted some parts that needs grinding..

 ..some more...

...and some more that would bore you to death if i show it all. See some parts of it is already rusted, so a rub with sandpaper and recoat them with primer.

Primer phase is now done, and the a crack showed up! This means further delay to the painting process.
It is now being done last saturday with some MIG welding, and sandpaper and primer on the affected parts.
Flat black paint was already bought yesterda, but CLear for Flat is finished..only available next week.

Gaskets

Hi All,

As the overhaul continues, i have come towards near completion. This is the time when i need new gaskets all over.  I need new gasket for Clutch cover, i can still reuse my old one but that's wrong, at least not up to the level that i bring the engine now.

But what i really need is the gasket for flywheel cover, where i didn't have any in my stock, nor it was not there last time. I have searched all over for it, but no shop keeps stock. Now i remembered back in the old days, when i couldn't find any parts for the bike. Well, some things doesn't changed much.

So, the solutions is i have to make it on my own, using the cover to make the template. (i bet you guys already knows this) The gasket material is bought a long time ago, 0.8mm gasket paper for universal usage.

I have a punch to make the holes, but since it's already late at night and i have complaints from neighbours downstairs about noises, i need to find other ways to make the holes. Paper Puncher was my bet, and it does work perfectly. How much energy needed if i use the punch, but the paper puncher makes me wonder why i bought the punch at the first place.

The gasket is now completed, now i just need to re-thread back the bolt for the clutch cover, my flywheel side have been done previously. I lubed the bolts before assembly, and torque it to 10Nm configuration for all the bolts.

It arrives!

Hi,

Yesterday, the item that i bought on Saturday arrives at the office. It was fairly quick as normally my 'other' items came in 2-3weeks after i click "Buy-it-now" button and totally forgets it when it does arrive.

Behold...

RC Valve Servo, as mine is not working anymore. I just stuck it at the wide open position but it must be ridden properly to make it work.. imagine high rpm on a short go-kart track..

Standard flywheel, in case i need to test it for "10KM on a public highway at night". LOL. Just teasing, my bike got no battery to support that kind of activities.

 

I have been continuing to refurbish the engine, i am at the final stage now, as lack of gaskets makes the project hold for now. Even with lack of gaskets, i managed to keep focused on it up until 3:30am, only 4 hours to sleep before i got to work. Duh!

New battery..or lack of one!

Hi All,

I remembered that my bike have this 'epic' problems with the battery.. because it runs on a Total Loss ignition system, i have to charge the bike every single time i need to start the bike. Apart from that, due to minimal bodywork i have on my bike, i did not have any proper mounting or battery box.
My last resort was to hand it out to a welder, and he just tack a steel with 2 bolts and call it jobbed. What a loser makes that kind of job! i will update the picture here if i remembered.

So yesterday, i bought this so "Battery Eliminator" that was suppose to work, with a bike that needs a battery to run. It does not hold any charge, and i need to mention LIGHTWEIGHT of the thing.

Due to the fall of our currency, i bought it at a higher price rather than if i bought it last year when i first saw this being sold at the eGay. Battery Eliminator is essentially a low ESR computer grade capacitor that takes the place of a traditional battery. Highly recommended for track bikes.

"Developed, constructed and used successfully for many years on most 2T bikes by a two stroke junkie.

This device eliminates the need of a battery on magneto type ignitions. 

Less weight, less mass, environmental friendly, no danger of acid spills/ corrosion, maintenance free. 

It will straight fit any Tzr250, Tdr250, Rgv250, Nsr250, Rd350, Rd500 bikes and also most single cylinder bikes. Though, it will not work on racing machines that are running a total loss ignition system. "

 

Other details :

a) less weight, less mass. Compare the 50grams of this small device to a usual battery 

b) no danger of acid spills on competition machines

c) no need to use a charger when machine is not in use for a long period of time. Bike will start normally even after months of storage. Needs no maintenance, just plug and forget. 

d) can be used with 6 or 12v, positive or negative earthed systems. 

e) environmental friendly 

f) It will boost spark as it does not overload the reg/ rec trying to charge itself as a normal battery will do. Better starting, no misfires!

Specs: 

Size is 31x48mm and weights 50 grams. 

 

More work..

Hi,

Last Saturday as i asked around with my friends, friend of a friend, i manages to source some item that i need for the overhaulin progress. Piston ring, a virgin magnet ( me magnet have been...de-magnetized previously for the short circuit tracks) and a used RC Valve servo. My Servo is not working and i have tried to fixed it but no luck on that.. all this is in ONE MORNING! I was really shocked because previously this is not possible in 2009-2011 when i was racing with the bike back then. This shows how many NSR SP is there in Malaysia.

NSR SP Rings (only needed top ring)

Used flywheel. Will looks great after a polish... i hope!

The RC Valve servo proved to be in a good working condition.

As raya celebration continues i couldn't find a better time for the engine.. However i can sneak in a couple of minute to finish up a few chores.

New repainted Magnet cover.

Sealant was added to the mandatory mating surface under the reed valve housing (where the crankcase joint)

The mess...wifey give 2-weeks for the toilet to be cleared. :(

Engine Overhaulin'

Hi,

Last weekend i managed to get physical with the engine. Though i was only planning just to look at it and thing gets out of hand, one bolt after another and i have the piston in my hands! I should have clean it out first as that is the number one rule for engine, as any grime or even a dust entering the engine would result in a horsepower loss.. i felt sorry for the again but i did manage to avoid any dirt to fell inside the engine. That's because i only open up the magnet cover and the clutch cover only.

The engine with crudes and all sort of grimes attached to it. It's like giant magnet for collecting dirts!

 V FORCE 3 is still intact with good condition. Current production is now V Force 5! Wow i really left the scene for quite a long time!

Pistons and even ring looks in a really good condition! Previously i won't touch and engine if it's not broken :) This is more like a preventive maintenance, and the fact that it is being left for almost 3 years makes it in such a mysterious status..

I should have not worried at all since the piston, the cylinder, head was in near perfect condition. Note the slight ash left at the head, which will rinse off with a wipe from a kitchen towel.

Previously i must have forgotten to insert another ring.. or is it? :p

Jetting was quite spot-on..no need to worries about lean. This makes me wonder if i can put smaller main jet to improve performance.

New Tools

Hi All,

Yesterday i bought a tool that i have been dreaming for so long.. the Torque Wrench!

This is a must have item, for anyone who owns,race,repair and sells bike! I couldn't imagine my life without it..with so many broken bolts,leaking coolant etc.

It is a cheap one, i believe it is made in Korea or Taiwan. That's what i willing to spend on this item, considering so many task need to be done, projects need to completed an all.
It is rated from 5-80Ft.lb, should be good but some M6 and M8 bolts won't do on this, which is what mostly the engine bolts is. It is 3/8", and needs an adaptor to fit 1/2", which is what most of my socket is.
Price was RM125, exc GST.

Cleaning

Hi all,

Yesterday the cleaning starts. i don't know how many post will be about cleaning alone as the bike is really filthy.. so i hope you guys won't feel bored as i speak.

Sorry i don't have any 'before' picture of the frame, as it was in a shameful condition. i afraid my camera will get broken due to the crap from the frame alone. Grease, chain wax and all the rain brought out a village of grime. I should use degreaser but as i am reducing cost so i use normal laundry detergent.Might have to give it another go then..

This really shows how bad it is painting the frame with the engine in place,and swingarm still attached. It is a best idea to strip to the bare frame and paint it all. At this point i have come to an idea to powdercoat the frame to matte black, and i know a place not that far and quite cheap, but the quality is not the showroom / trailer queen quality. I'm also don't have the budget for the moment but since this is not an urgent rebuild i might give it another thought.

Another new beginning.

Hi All,

I hope i can get the same audience same like last time. I have been contacted and prompted several questions regarding my bike and it's a shame on me, as i have just left the bike...untouched.

Years passes by, along came new bike a Suzuki GSX-R 600 K4 version, a marriage, friends loss and new friends gain along the way..all the LIFE stuff. I have been totally neglected the bike, even deep down inside i still wish i had the money to keep the bike going..

Fast forward, yesterday 21st July 2015 marks a new beginning for the bike. With plans to rebuild the bike up from every nuts & bolts given  TLC, new paint all around and shit. I have disassembled the bike with the help from my BFF Mr khaleq himself, who used to race with me with his Kips.

Long story short, it takes about an hour to fully disassembled the bike, and been forced to fit inside my Wira aeroback 1.3 : ). I bring the car to work this morning, and will unload it after going back from work.

Image shown is for illustration purpose only.