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:
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.
It was time to put the motor
together. Everything went smooth. As you can see, I went with a
larger oil pump made by Daytona. Thanks to TK Racing products for
hooking me up with that, and the tritium thrust washer for the crank, as
well as some other light weight top secret parts! ;)
I also painted
the frame black, I used ceramic paint and baked it on with a torch after
every coat (put about 8 coats on it)... I'll get it powdercoated after I get my exhaust in. I
didn't want to have it PC'ed and then have to weld on a different
exhaust hanger.. So, this will do for now.
UPDATE: 3/20/2010
Started on getting the bike back
together, everything went on smooth and I installed the stock NSF
exhaust for now, till I either build my own custom undertail, Jemco
makes the one I've asked for or I'll just install the old exhaust I've
used in the past. Just waiting for my custom braced swingarm to get here
and the bodywork to get painted. I've got a few more plans for the bike,
but it is just small changes, like new pegs, stainless steel brake line,
etc.. Here are some pics of where I'm at now..
April 10th 2010 Update:
Got to ride the bike on the track a
few weeks ago and got the carb dialed in with the correct jetting now.
I used the stock NSF exhaust for practice the other day, but I just
installed my old custom exhaust for the first race next week. I
think I'm going to build my own exhaust, a friend can bend me the header
and other stuff, I'll just need to find a exhaust can, and I might have
one that will work?? Also, installing an oil cooler, just waiting
for a few fittings to come in and I will plum it up!
Anyway, the bike is SUPER FAST!! I
can't believe how much low end and top end power this motor has now.. It
wants to rip your hands off the handle bars and I've got to be honest...
it scares me! HAHA When I went to the track (the videos below are of
that day) I had gearing set up for our longer track, BeaveRun, and the
bike did GREAT with that taller gearing on it at the short track. I
think I'll run a 40 tooth rear with a 13 front, that should be a good
combo!
I should have my bodywork back from
my friend Paul who is going to do a sweet paint job soon!!
Check out the videos below: Video on
left has NSF exhaust, the other has my custom larger exhaust!
On the track with stock NSF exhaust:
Well, my first race went really
well! I ended up getting three 1st place finishes, and one 2nd
place finish. This bike is crazy fast and keeps up with the CRF150R's
and 85cc two strokes! Should be a good racing season for me and
the bike in our F1 class racing with those faster bikes! Below are
a few pictures of the bike with new bodywork/paintjob installed.
Still waiting on a few things like exhaust, swingarm, and new pegs.
Just some random pic's of the oil
cooler setup, and motor after one race under its belt! LOOKS GOOD.. no
problems!
And Motor mounts for this motor swap
are for sale! Contact me at:
rdracer4@hotmail.com for more info or click on the for sale section on
this website!
