Project KICKER's MC21 Project

They're amazingly light. And they're pretty well made. I mean, for the price alone compared to Japanese exhausts. But! I reckon there should be a better flange and head on the expansion chamber because I think the Tyga guys recommend to silicone the exhausts to the flange but I reckon a seal of some kind would be better. So I put an O-ring on the flange so it hopefully will seal it up nice and stay nice and tidy (also so I don't have to wait 24hrs to ride if I remove the pipes for cleaning). I had some HRC pipes though and I think they bolted up a similar way. The springs supplied by Tyga are also very good. The whole pipe is supported when you put the springs on (which meant making those plated was easier).

 

I will do. I just need to adjust the RHS pipe so it is a bit straighter and it should be alright.

 

So took some photos of the bits I made so the expansion chambers would mount up. I am thinking I'll try and bend some steel since the aluminum isn't strong. Or make exhaust hangers for the silencers. Or both! Nonetheless, these bits of aluminium were scraps out of the garbage so I still need to cut them smaller. I'd muck around with them but the workshop is a toasty 36 C so I'm not too keen to do anything in there today.

 

So got back to the NSR and sorted out mounting the elctronics. I originally wanted everything except the battery and the PGM to be inside the frame but it's fairly tight and I'd have to modify the wiring harness and I haven't fully decided if I like the trail tech unit yet. I am going to put my shifting lights from the MC22 on the MC21 though because they might be actually useful on this bike.

And here's what I quickly put together for the R/R, Fusebox and indicator relay. They're mounted to two pieces of aluminium and bolted to the subframe. There's a fairly sizable gap between the seat so hopefully it doesn't get too hot.
And I was meaning to do the rear brake since I bought a part I needed but as fate would have it I have lost it. So I need to tidy up and hopefully find it.

And here is a modified dirt bike trailer to fit a CBR600. I have had the 600 on it before hand but it was super sketchy, especially using the ramp it came with. There's now two ramps which store away neatly. The new ramp has some flex on it too but I really didn't want to add much weight because it's already a fairly heavy trailer for its size. In hindsight, I would have cut the channel in the middle and just got one large piece of plate for the middle section, instead of 3 separate pieces. But at the time I wasn't sure how much it would cost (like, $110 for the plate) and it works fine. A coat of paint and it will look new again!

Also, if you see a trailer being towed north with a CR125, NSR250 and a CBR600 in about 10 days... yeah, that's gonna me.

 

Also, found some decals which I totally forgot I had including a matching set of Honda decals for the bottom of the fairing. So all I need now is some Honda Wings for the tank and I should be set in terms of some minor graphics for the decals.

 

So the bike looks mostly finished but there is still a few odds and ends to do. I lost the guide clip for the rear brake (brand new one still in the Honda bag, somehow grew legs and walked away) so I'll have to order another one ($10)! And of course when that arrives the other one will pop up.

But today I used some aluminum strip to make an exhaust hanger. I just drilled through the subframe to mount it. Looks fairly nice I think, and light. I previously bought the mounting brackets for the MC18 sub frame and thought I could use it here but it was made from steel and is much much heavier, and was too short.

 

So I'm trying to get the NSR finished. 3 years in the making but it's finally getting there. I got the opportunity to take a pretty significant shortcut though. I got the opportunity to purchase some pretty special body work. From the onset this was supposed to be a tribute bike to the last master of the NSR, Dajiro Kato. He was the last rider to win on an NSR250. I was so hard to find the right decals and was looking to be an absolute mission to do it. I'd need to make them myself. But I emailed Paul from Tyga Performance who still had his old body work for his NSR lying around and was gracious enough to sell them to me! At a pretty hefty discount too! So it's the Pedrosa body work but I'm a Pedrosa fan and it's in relatively good condition. I'll be sure to include the #74 tribute tank decals too.

Also, because (for some reason) the Tyga bracket, which I'm pretty sure is an OEM bracket from another bike, doesn't fit with the MC21 bracket, I have resorted to using a pressure switch. Now I just have to wire it up. The good news is it works! Tested it with the good old multi meter!

I had to remove the wheel to remove the brake assembly as I didn't want to get brake fluid everywhere. Initially I was going to use the stock OEM brake switch with the MC18 master cylinder but for whatever reason the MC18 master cylinder wouldn't work. I noticed this when brake fluid was leaking out of the bottom of the master cylinder. Good thing I used some old brake fluid to prime it!

The to-do list is significantly shorter, thanks to Paul from Tyga Performance.

I need to:
Fit the body work

Purchase an MC28 fuel tank (Paul has advised me the MC21 won't work). My MC21 tank needs work anyway, cheaper to just get another.

Get the wheels painted black and the tank colour matched.

Start it up and ride!

 

So I'm at a hold point on the NSR because I need an MC28 fuel tank. I found a cheap one on Rinkya but not ready to purchase just yet. I did consider just cutting the body work but I know it will fit the MC28 tank perfectly. Besides, the MC21 tank needs a fair bit of work anyway. I made up this bracket which holds the fuse box! Works with the original clip mechanism.

 

Nah, never see any parts for MC28s from Japan. Have people been wrecking MC28s on there before? I want to get an MC28 rear end and wiring loom/dash eventually too.

 

Hmm Interesting. They don't have any MC28 stuff. I was on Rinkya and found a tank although the translations from Japanese are quite ambiguous. I just got my tax back so I think I'll take a gamble with a cheap tank.

 

Wow, thanks! Unfortunately both tanks are quite second hand (quite a few dents) but I am just gonna bog over them and prep it for A1 to paint. I bought the slghtly cheaper one as I will recoat the inside.

Thanks so much for the tip too! I appreciate it as it's significantly cheaper than the Yahoo Auction way.

I considered an MC28 speedo and wiring harness but I think I'll just make it a complete bike before I modify it further.

 

So after much delay, I was inspired by kiffsta's 2 stroke post to get back to work on the NSR. Due to life, home improvements and other things the poor NSR fell off the radar. But, the dream continues!

The only big issue that dissuaded me was that the body work I am fitting is actually MC28 body work, in fact, the old TYGA body work from Paul's bike. I was advised that all I would need was an MC28 tank. The tank I got was super rusty. I ended up removing crap load of rust and got the inside fixed. Then I tried to fit it....



As you can see, it didn't fit. So I had a few options: modify the fuel tank (front tab) only or modify the subframe / tail or modify the fuel tank (rear tab) and body work. I opted for the front so I today cut off the tab and have plans to get a plate with tapped holes to bolt a mounting adapter to. This means the tank could also go back onto an MC28 without too much effort.

The good news is without the stock mounting tab it fits!


Does anyone know a company that does CNC work? I'd like to draw this up in autoCAD and get someone to mail it to me. I have a mate who's an amazing boiler maker to weld it for me/

 

Well as usual I am currently working on the 450X now... But still keen to get the NSR on the road. I am working heaps over Comm Games so I plan to go on a spending spree on WeBike soon.

I plan to modify the fuel tank myself now which will help me enter the metal working world. Eventually I want to fit RS125 body work to the NSR so I plan to purchase a MIG welder, grinder and a muchly needed vice to do that! But I will keep you in mind for any potential CNC stuff in the future. And of course for the maiden ride!