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Street Plated NSR50 Project

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Discussion starter · #181 ·
OK I cleaned up the carbs and more specifically the needle attached to the float bowl last night. But the float bowl still keeps getting stuck it in the up position and won't let gas into the carbs.



I'm going to go buy a bottle of the fuel system cleaners and stick it in the gas tank to see if that can somehow loosen the needle from getting stuck next.
 
#182 ·
FourDoor said:
OK I cleaned up the carbs and more specifically the needle attached to the float bowl last night. But the float bowl still keeps getting stuck it in the up position and won't let gas into the carbs.



I'm going to go buy a bottle of the fuel system cleaners and stick it in the gas tank to see if that can somehow loosen the needle from getting stuck next.
Click to expand...


R,



float needle p/n 16155-NLA-003, H/C #7739428



CARBURETOR ASSY. (PF70M) p/n # 16100-NLA-003 H/C# 7739402



Look up Service Honda Home of the CR500AF - Honda Motorcycle Parts and see if you can order these and or if in stock.....fyi.



Otoh, I do have a spare 04 NSR carb ;)



I can bring it with me to the BBQ on Sunday
 
#184 ·
Gonna be watchin this thread, just picked up one for myself :D
 
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Discussion starter · #185 ·
Well the only update I have at the moment is that the NSR is at the shop getting it's fork straightened out. :(



I had a little incident a couple of weeks ago where the NSR met a guardrail after it bucked me off in only what i can call a little mini high-side. Damage were some rashed plastics on the front left, part of the rear tail has a nicely sized chip, broken foot peg, and the unfortunate tweak to one of the forks.



It appears that part of the reason of the crash at the moment is that the stearing head may not have been torqued down all the way as there was quite a bit of play on the triples after inspection. Possibly the new tapered bearings were not seated all the way during the install which would explain the bounceyness that I was describing on the shakedown ride.



So 1 step back in the progress of the bike. But Phase 2 is currently undergoing research as funding for the project has been limited as of late.



On the bright side, I have an XR100, motor mounts, exhaust, and lighting coil already for the NSR awaiting to be dropped in. I just need to figure out how to do the wiring for the lights from the new stator and I can drop it in and ride as is to get a baseline before the XR80 tranny and whatever big bore kit makes it onto the bike. :D
 
Discussion starter · #186 ·
Got the bike back today and the damage was bent fork, bent front axle, tweaked lower triple, and of course the loose steering head. All of that is fixed now but there is now one more problem to solve. And it was possibly one of the major contributors to my crash. There is about a 1/4" gap between the speedo pickup and the left fork. I don't remember it being that large of a gap before (probably since I was too excited putting the bike back together) but when you tighten the front axle in, it binds the front forks and causes them to not travel freely. Hence me thinking/feeling that the RJP forks were way too stiff. :(



Here is the gap between the speedo and fork:

Image




Here is the setup on the 2004 NSR without the speedo:

Image




Anyways, the problem I see is that I'm not missing any spacers here. The right side where the caliper is looks perfectly fine, spacer, dust seel, and bearing.



Image




But on the left speedo side, it's just the speedo pickup tab on the wheel, the gear to latch onto the tab, and the pickup assembly casing itself. No spacer. How can I tighten down the front axle and not bind the front forks? Should I get a set of spacers to cover the 1/4" gap? At that point I need to find a way to put a little stopper for the speedo pickup assembly since right now it rests on a stopper tab on the fork leg.



Any thoughts/ideas on how I can fix this? It's really a night and day difference in regards to how the forks travel up and down right now with the axle tightened.
 

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Discussion starter · #191 ·
The forks were checked and straightened. At least the right side fork was straightened. If I rotate the top fork leg, wouldn't it rotate the entire lower fork assembly as well and I wouldn't be able to tell (at least easily) if it is shifting since the fork legs with the flattened axle area would be rotating with it?



Brad, no I don't remember any kind of rubber seal in there. Off the top of my head the left assembly goes:



- Wheel with the little metal cup sitting on top of the wheel. This metal cup has a tab on the inside of it that the speedo hub picks up on.

- Speedo gear that connects to the little speedo cup

- Speedo pickup case (in the picture)



Is there supposed to be some kind of other seal between that little metal cup with the tab and the speedo pickup case?
 
#192 ·
R,



Take a look at your before and after pix. I beleive there is no spacer on the left side, only the right. But verify.



Did Ray inspect the left fork tube as well? I suggest it should be, if not.



as shw911 said, loosen the left upper fork tube and clip-on from the triple. Loosen the axle bolt, then by hand, turn/spin the upper tube and watch for any deviation along the fork tube. With a gap that large, you should be able to conclude whether it's straight or bent.



Btw, take a close look at your lower triple too and ensure there is no damage.



If you don't have front stand, I can lend you mine. Other option is to support the front end off the ground using tie downs from the rafters in the garage. You'll just need to find a way to stablize the front end while it's off the ground. Let me know it you need to use the stand.



If you need any help, let me know too.



FourDoor said:
The forks were checked and straightened. At least the right side fork was straightened. If I rotate the top fork leg, wouldn't it rotate the entire lower fork assembly as well and I wouldn't be able to tell (at least easily) if it is shifting since the fork legs with the flattened axle area would be rotating with it?



Brad, no I don't remember any kind of rubber seal in there. Off the top of my head the left assembly goes:



- Wheel with the little metal cup sitting on top of the wheel. This metal cup has a tab on the inside of it that the speedo hub picks up on.

- Speedo gear that connects to the little speedo cup

- Speedo pickup case (in the picture)



Is there supposed to be some kind of other seal between that little metal cup with the tab and the speedo pickup case?
Click to expand...
 
Discussion starter · #193 ·
Both fork legs were checked along with the entire front end by Ray. But based on the comments here I am guessing there is still some kind of small tweak in the front end that needs to be fixed all be it the fork or the triple.



I'll ping you about the front stand as the front stand I have goes on the bottom of the fork legs and not the lower triple. That plus I have no rafters in my garage to hang stuff from.



I'm pretty sure there is no spacer between the speedo pickup and the fork but will see if I have a detailed pic from before to confirm.



The sad part is that if I tighten up the bolt on the front axle, the front end LOOKS to be just right. But the forks no longer slide up and down freely and makes the front end very very stiff.
 
#195 ·
Seriously, your forks should not bind (stiction) while travelling up and down and your front wheel should spin freely (not over-tightened), nor have any free play between the forks.



The stand I have slides under and within the lower triple. Let me know when you want to borrow it or have me come over. I have another just like it, but needs a "pin" welded onto it....the portion that fits within the hole of the lower triple.



Let me know ;)





FourDoor said:
Both fork legs were checked along with the entire front end by Ray. But based on the comments here I am guessing there is still some kind of small tweak in the front end that needs to be fixed all be it the fork or the triple.



I'll ping you about the front stand as the front stand I have goes on the bottom of the fork legs and not the lower triple. That plus I have no rafters in my garage to hang stuff from.



I'm pretty sure there is no spacer between the speedo pickup and the fork but will see if I have a detailed pic from before to confirm.



The sad part is that if I tighten up the bolt on the front axle, the front end LOOKS to be just right. But the forks no longer slide up and down freely and makes the front end very very stiff.
Click to expand...
 
Discussion starter · #196 ·
Greg, where did you get the spacer from? If the little tab on the cup doesn't need to rest on the fork, I will do the same as you. That is after I double and triple check that the rest of the front end is straight.



D, I sent you a PM about the stands.
 
#197 ·
If they are free without being tighten and binding when the axle is snugged I wonder if the absence of the spacer is pulling them out of alignment when tightened?



I have the big spacer that replaces the speedo cup if you want to play with it.



I think we need another group ride before the rains!
 
#198 ·
FourDoor said:
Greg, where did you get the spacer from? If the little tab on the cup doesn't need to rest on the fork, I will do the same as you. That is after I double and triple check that the rest of the front end is straight.



D, I sent you a PM about the stands.
Click to expand...


I ordered it from East Bay Motorsports with a part number from Z. It is 04 NSR. They did look at me funny but eventually came up with it.
 
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