Planet Minis

FourDoor

Thanks Shawn. I was just looking over J-Tradings website last night looking for misc stuff and didnt see the NSF pipe for sale.

But I think I'm gonna hold off on any future motor purchase stuff for at least another couple of months to make sure I have enough $ for the rest of the "basics" that need to be done first. I'm considering this the Phase 1 of of this project (get it streetable with the stock 50 motor). Phase 2 will be the big motor transplant...

FourDoor

OK today's update is chopping...

I hacked off the end of the subframe. So far it appears to be have left the subframe to be pretty sturdy still since that little tower in the middle holds the 2 side pieces together. I spent the good part of the night just sitting there grinding away to make all of the old welds clean/flatter.




After that was done, I started to grind away at the NSF tail itself. I trimmed sections of the underside of the tail so that I could have the tail clear the subframe without hitting. After grinding away with the dremel for a while I was finally able to get the tail to slide in and out without it hitting the subframe. Now once I install some D-Ring fastners, I will be able to remove the rear tail easily at a gas station to pour in some 2stroke oil.

Attached Images

	NSF-NSR_Tail (14).jpg (50.6 KB, 145 views)
	NSF-NSR_Tail (15).jpg (45.6 KB, 144 views)
	NSF-NSR_Tail (16).jpg (74.0 KB, 141 views)

FourDoor

I then got a little distracted and decided to test fit the rear original fender/undertail. This is what it looked like before I brought out the Dremel:



After some chopping to the sides of the rear fender where it mounts to the rear subframe, I was able to get the tail to sit on top.




I think after seeing this, I may just leave the battery in its stock location and find something to cover it. I still need to come up with a brake light/signal light solution for the rear but at least the tail is now ready to get the mounting tabs fabbed/welded on.

Attached Images

	NSF-NSR_Tail (17).jpg (50.6 KB, 141 views)
	NSF-NSR_Tail (18).jpg (33.3 KB, 140 views)
	NSF-NSR_Tail (19).jpg (39.0 KB, 138 views)

shawnbassett26

looks good to me.
~Shawn

FourDoor

Thanks to Manimal for walking me through how to clean a carb. Thanks to him I opened and cleaned my first carb! LOL

Upon opening the carb, the float bowl looked worse than it actually was. Looks like the old rusted gas stained the inside of the carb but it was not that gummy inside.



So after taking apart the carb and jets (looks like the main jet is a 100), I sprayed everything liberally with the carb cleaner and wiped down the parts that looked like it had residue with some shop towels. I cleaned out the jets and made sure there was nothing clogged.

[img]http://www.planetminis.com/attachment.php?attachmentid=37021&d=1216200338[img]

After spraying and cleaning, I reassembled the carb and put it in a zip lock bag for now. I was pretty proud of myself for not losing anything. LOL



So now that the carb is done for now, I was wondering if anyone knows what aftermarket air filters fit the stock carb? Do the CRF50 air filters fit? I don't really want to re-install huge the OEM air box.

Attached Images

	NSR50_CARB_01.jpg (53.4 KB, 119 views)
	NSR50_CARB_02.jpg (35.6 KB, 4 views)
	NSR50_CARB_03.jpg (26.3 KB, 119 views)

FourDoor

And speaking of huge OEM parts, anyone know what this big yellow plastic thing is that is connected to the intake manifold? My guess is that it's some kind of resonator box but am not sure. Can I just take it off and put something like a little breather hose and filter?

Attached Images

	NSR50_92JDM_MOTOR_01.jpg (54.2 KB, 121 views)
	NSR50_92JDM_MOTOR_02.jpg (36.8 KB, 122 views)

wreck

I'm guessing it's a boost bottle, Opening up the intake after the carb will give you a lean burn if it runs at all.

FourDoor

I'm not familiar with boost bottles, but I'm guessing it provides some kind of added back pressure to the system?

I'm so tempted to start tearing at the motor and start modifying/cleaning it but I know I'll be swapping motors in a few months so I must resist the temptation for now.

shawnbassett26

On a YSR its the boost bottle, most people remove it.
~Shawn

FourDoor

I guess I'll just leave the "boost bottle" there for now as I don't really want to mess with the bikes a/f mixture right now (aside from changing out the filter).

Speaking of which, Anyone know which air filters from other bikes fit the the stock carb?

ysrbo

What is J-Tradings website.

FourDoor

ysrbo

Thanks nice build.

shawnbassett26

Get the gas cap problem solved?
~Shawn

FourDoor

Yup. SpeedyCorky helped me out by posting the part# for his Vortex Gas Cap. In summary:

The Vortex CP402 aluminum gas cap fits the NSR50 tank which is actually designed to fit the following Kawasaki's:

ZX650R 2006
ZX6R 00-06
ZX9R 00-03
ZX10R 04-05
ZX11R 97-99

The frame is out getting tabs fabbed up and welded to the subframe but I unfortunately won't be able to get it back until early next week.

After it comes back, the frame goes to powedercoat finally and I can start to finally start to rebuild the bike.

FourDoor

Another small update. Levers:

So I decided to see if my stock Nissin brake master cylinder would clean up if I sanded and polished the rash that was on it. Well it came out decent enough that I decided to keep the stock brake master cylinder for now and order some of the ASV levers. Also, this worked out for me since I needed a new clutch lever with perch. I was thinking of ordering something like the CRG clutch lever with perch, but that setup was nearly $200 so I decided to pass for now. Here is what I ordered for the NSR50 instead.

UNIVERSAL CLUTCH WITH PERCH Part# CMF30 $70.00
Also available in a “Shorty” version part # CBF35

F3 Series FRONT BRAKE LEVER
SDG / Extreme=2 0/ Thumpstar / Pitster Pro Pit Bikes.
Part# BHF38 $70.00


The newer BHF38 front brake lever didn't require the lever mod I had posted earlier to get it to fit nicely into the stock Nissen brake master cylinder. But as you can see, it still didn't have the little tab needed to push in the brake light switch like the TTS and OEM lever did.



So a little aluminum, pounding, cutting, some JBWeld, and patience netted me this:



Now with my makeshift brake light tab, I can use the stock brake light switch that came with my NSR.



As an alternative you can just use the banjo bolt switches like the one from Baja designs. This was my secondary option and will be my primary option if/when I switch over to a Brembo brake master cylinder in the future.

https://www.bajadesigns.com/NET/imag.../120104big.jpg

I'm happy with the look and build quality of the ASV levers so far. Can't wait to try them on the actual bike when its all pieced back together.

Attached Images

	NSR50_ASV_Levers_01.jpg (54.3 KB, 86 views)
	NSR50_ASV_Levers_02.jpg (52.4 KB, 85 views)
	NSR50_ASV_Levers_03.jpg (55.7 KB, 86 views)

shawnbassett26

4DOOR, levers look good. Keep it up.
~Shawn

FourDoor

Thanks Shawn. I'm pretty much now just waiting for the frame to come back and hopefully I can get it powdercoated this week. So I'm just trying to do the little misc stuff done. Then I'll be out of town for 3 weeks so the project will once again go on hold.

I'm probably gonna go through the wiring system next and find out whats what as there are several plugs that came disconnected on the bike. Hopefully I can document whats what and provide some kind of reference point for someone else in the future if they end up with a similar JDM NSR50.

Mike_the_minibike_man

Wow great job... I've been away with the military for a bit but the tail work you did was VERY helpful for me. I think I'm going to just cut my tail section off as well. I don't the high bridge at the end (as mine is an 04) but since I have to take apart the bike to put on my 70cc athena big bore kit it is the perfect time.

I've been holding off cause I don't really know how to do this stuff AND I can't stop riding my bike (even unfinnished) but i need to get off my but and do it.

FourDoor

Thanks. I've been looking for anything documenting how to mount the NSF tail on the NSR for about a month now and couldn't really find anything. I was browsing Japanese sites and using babelfish and google translator which produces some really funny translations sometimes LOL

I'm glad this thread helped you. I'll take pics as soon as I get the frame back but I'm going to be out of town for 3 weeks starting tomorrow so the project is going on hold. That means I won't be able to ride the NSR on the street at least until September at the earliest now!