How I Transformed a NSR into A NSF...

This is how I transformed my 04 NSR50 from a smoking 2 stroke into a fire breathing Takegawa 124cc 4 stroke that eats up 2 strokes for breakfast! 

Fore details on the motor build, please scroll down to the Takegawa 123cc Stage 3 motor build part of this page. This part will show how I was able to mount the Air Tech NSF bodywork to my NSR, as well as mounting a Jemco/WRW NSF exhaust to my bike. Some cutting and welding is needed for this transformation to be complete, but any back yard shade tree mechanic with the right tools can do this with no problem.

Let's get started with the frame mounts. As you all know, I make and sale the CRF/XR100 motor bracket kits for NSR framed bikes, so I took my bracket kit that I've been using for YEARS now with no problems and I thought I would beef up the front part of the frame since I'm now running a 20hp motor, I wanted to try and beef up the motor mounting points as much as possible to stop the motor from twisting the frame.  I've looked at many TRUE NSF's pictures and a few in person and thought I would "copy" what HRC has done to the frame.   If you look at the front two down tubes on a NSF, they are braced at the top, and the tubes are extended down a little longer to accommodate the CRF/XR front motor bracket.  This will be helpful since my motor puts out some much HP and torque, it will help brace the front end of the motor. I welded everything up and painted it so it won't rust..

Then I got my new Jemco/WRW NSF exhaust.  Man was I happy to see this come in the mail!  It is stepped up in size from the header to the exhaust end at least 5 different times!  It is truly a nice exhaust that is proven to put out some serious HP and torque!

When I first put it on the bike, it was clear that I needed to make some exhaust hangers to hold it, not only in the back, but on the side like the NSF's have.  So, after looking at the NSF hangers, I tried to copy one for myself, and it worked out great!

After the exhaust was done, the rear shock came in from www.35motorsports.com  They refilled the nitro, fresh oil, and a new HyperCo spring that is suited for my weight and riding style. They also moved over the banjo bolt for the remote reservoir to point to the other side, so my undertail exhaust won't hit it!  Overall, it works a lot better then the stock shock! Very happy with 35motorsports... call them for your suspension and motor needs!

Next, the Airtech NSF bodywork came in, and it was time to start making mounts for it.  The standard NSR bodymounts are junk, I've never liked them and they would bend at the smallest crash or fall, so I thought I would take a page out of HRC's book again and copy the NSF bodywork hangers. I ordered online from RonAyers.com some new NSF bodywork nuts and screws.  The "nuts" are plastic inserts that go inside the conduit and are held in by a pin. You'll see what I'm talking about in the pic's below..  I cut off all the stock hangers on the frame sides, and welded up a steel tube big enough to hold a small piece of conduit.  I then cut the conduit, slid the plastic insert in and pinned it in place.

For the upper fairing stay mounts, I once again copied the NSF's and made my own.  Using conduit, I bent it to the shape and size I wanted it, welded on a brace and a pin for the upper tripple bolt and BAM.. you've got a upper hanger.  For the front, I just took a piece of conduit again, welded on some mounts to hold it in place, and use a bolt to hold it on the front fairing's mount inside the bodywork. 

Next was to install a Daytona outer rotor kit (ORK) to the XR100 motor... man did it shave off a lot of weight from the ignition!  Comes complete with new wire harness, CDI, and 4 programmable ignition curves!!

Then, I went to local engine builder, and custom parts maker Todd Patton of http://www.tkraceproducts.com/  He made me a spacer to take out the idle gear on the motor, since I no longer have a kick starter, that gear was useless weight just spinning inside the motor... it is no longer there!!  After that, the rest of the motor went together with no problem and I started the rebuild process!!

Next was to figure out what I was going to do for paint.. I have always loved the Repsol Honda bikes, and the MotoGP one's in particular. I'm also a big  Andrea Dovizioso fan, and my race number is the same as his, so why not do a replica Dovi MotoGP bike!  This is what it came out looking like...

Here is a video of it running.. Aug 2011

Takegawa 124cc Stage 3 Motor build

 I have raced my 2004 NSR in many different trims and motor configurations.  From bone stock, to built 65 and 70cc motors, to a XR100 motor with a BBR120 kit.  Now, for the 2010 racing season, I'm going to be transforming my NSR to accept a NSF undertail exhaust, a custom built swingarm that is going to be 20mm longer and braced, a Takegawa 124cc stage 3 kit, Takegawa PE 28mm carb kit with NSF offset intake and a few other mods. 

I first want to thank Mitz from Tokyo Japan who I worked with to get the parts for my NSR/NSF. He was VERY helpful in answering all my questions and concerns about all the different options I had.  Once I did buy my kit, the shipping was really fast (took only 3 days for my items to arrive).  If anyone wants to buy trick hard to find parts that you can only get in Japan, or want to get parts for a better price, contact Mitz!  I highly recommend him! His contact info is:

Email:
mitz44@tokyolaunchpad.jp
website:
http://tokyolaunchpad.jp/ 

Now, here is what I have done to my NSR and the XR motor over the offseason getting it ready for the 2010 season.

First I striped the frame and since I am going to run a NSF exhaust with the NSF tail from AirTech, I had to cut some of the subframe off and weld on some things to get it to all work out. As you can see from the pictures, I had to add some seat posts (NSF rubber will be used to cushion the tail) and I still need to weld on a exhaust hanger on the hoop. By the way, I wanted to keep the seat back to give me more room on the bike, if I were to put it where the NSF has the seat, it would be very cramped! The hole between the tail and tank will be covered up with my seat pad. After I'm done welding on the frame, its off to to powercoater.

For the front suspension, I just adjusted the emulator kit a bit and cleaned up the internals, installed with fresh oil and it is ready to go! Rear shock is staying stock for now! Thanks again go out to Reuben Frankenfield of www.35Motorsports.com for doing the work on my forks last season and for the continued help. If you want suspension help for either a big bike or mini, he is the man to talk to!

After that, I split the motor and took out the kickstarter shaft and gear.  Since I do not kick start the motor at all (with the new Tak kit, kick starting a high compression motor is hard on the gears) this will save me about 2lbs of weight!  I had to figure out a way to block the holes both inside the case and on the case cover.  There is much debate if the hole on the inside has to be blocked off or not.  I figured that it was blocked when the gear was in there, so I made a set of block off plates out of alum, taped one of them, and put a bolt thru it.  (I will start making them for the public after I test it out this season). For the cover, I ended up using some automotive epoxy that can be used in motors and around oil and high temp areas. After I did that, I found out that     www.TeamCalimari.com    has a rubber piece that will block it off.  So, I ended up getting a rubber plug and will plug it along with the epoxy and should have no problems!

I then got the motor kit in.  Takegawa 124cc Stage 3 Superhead kit with roller cam!  I think the Takegawa kit is a thing of art and beauty.  The roller cam rolls so smooth, the cylinder is super light and has the oil cooler ports on it.  The Superhead is nice,  has huge valves and some port work done to it, and then the stroked/lightened crank is really nice as well.  Too bad all this beauty will be covered up inside the motor! I also did the oil jet mod that Takegawa recommends when installing the stroker kits.  They were having problems with the piston pin at high RPM, and the oil jet mod solved the problems.  Was real easy to do and only took about 10min.  

I also got the Takegawa PE28mm carb kit.  It came with the PE28mm carb, throttle, throttle cable, offset NSF intake and boot, as well as extra jets and hardware.  Very nice stuff and the offset intake is nice!  I'm going to add an oil cooler to keep the engine temps in control, I hope I can get this TRX450 cooler to work, if not then I guess I'll have to find a different one. I'll update what happens with it.

Now with the increased pressure the motor will produce, I was advised that a breather valve would be a good thing to have.  After getting a custom swingarm made, the motor and carb kit, as well as bodywork, I do not have the money for a nice ShiftUp, JRP, or Daytona valve cover with oil shower and breather valve.  So, I drilled my stock cover (added some gold bling) and made my own oil catch can. Should add a few extra HP, but it will help with throttle response and engine braking more then anything.