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Project KICKER's MC21 Project

Discussion in 'Your 250cc Projects' started by KICKERMAN360, Sep 15, 2015.

  1. KICKERMAN360

    KICKERMAN360 Well-Known Member

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    So I've been posting a fair bit about my MC21 project to the "What have you done to your bike today" thread and I thought I'd start my own thread to catalog my progress.

    So today I did a leakdown test and confirmed there is indeed a leak on the intake rubber, specifically where the LHS boost bottle inlet connects (the LHS cylinder was misfiring). I have another rubber inlet thingy but it's 2nd hand and also has a slight tear. So I'm gonna see if I can find a new one from somewhere (if anyone knows let me know!). I guess it's a lot better than a crank seal leaking!

    My uncle tends to hoard plumbing supplies so I was able to look around the workshop and find stuff to make what i sshown below. I made a similar thing to try and fix an expansion chamber (similar setup) so I had a fair idea. On this one I added the tap and pressure gauge. For the exhaust side, I found a large O-ring that was perfect but couldn't find another. So I just use a piece of rubber and an O-ring from an aldi o-ring set.

    IMG_1839.JPG IMG_1840.JPG IMG_1841.JPG
     
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  2. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    What is the part number for the left carby boot?
     
  3. KICKERMAN360

    KICKERMAN360 Well-Known Member

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    Part number is 16210-KV3-830. Most places seem to not stock it, or say it's discontinued. I'll be super disappointed if it's discontinued but I guess I can repair it if worst comes to worst.
     
  4. KICKERMAN360

    KICKERMAN360 Well-Known Member

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    The MC28 Part Number is 16210-KV3-950 and I think it should work too. RS Cycles has those, so I guess I can grab them if the MC21's aren't available. It's a shame these parts which degrade fairly quickly are becoming so hard to find.
     
  5. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    Looks like the left and right boot are one assembly from pictures. Is that correct?

    CMS has the latter part but it's 99 euros
     
  6. KICKERMAN360

    KICKERMAN360 Well-Known Member

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    Yeah, the one piece (which is a little annoying in some ways). Hmm, CMS has always been super expensive for some reason. That's around 200 AUD. I think RS Cycles is the way to go, about half the price.
     
  7. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    If they have it in Aus then go for it, no point waiting for international shipping
     
  8. aky141

    aky141 Well-Known Member

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    Can source on genuine from japan, let me know if you want link, was about 200ish
    but is genuine for mc21
     
  9. KICKERMAN360

    KICKERMAN360 Well-Known Member

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    Hmm, I did some looking and I found some places for around $100. I think I might buy a bunch and eBay them off, or keep them as spares. But for now I'll repair the current one with some RTV Silicone. Paul from Tyga says they don't make them either but I'm sure there are some floating around. Tomorrow I'll try the other 2nd hand one I have and see how it goes!
     
  10. aky141

    aky141 Well-Known Member

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    Damn it paul i sent him the link too XD
     
  11. KICKERMAN360

    KICKERMAN360 Well-Known Member

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    So I swapped over the intake rubbers and inspected the old one. Pretty obvious tear. I had noticed this quite some time ago hence why I had another one. I also have another second hand one that is in worse condition but I'm gonna insert a small length of steel rod and silicone it in eliminating the boost bottles and hopefully sealing it up. Nonetheless, the bike shouldn't misfire. I did a leakdown test again but it's leaking around my seal on the exhaust port so I'll have to think up another way to seal it. Progress is being made!

    IMG_1843.JPG
     
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  12. aky141

    aky141 Well-Known Member

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    Mine are exactly like that, need one of those and a chain guide 243454_206529416055213_5021931_o.jpg
     
  13. KICKERMAN360

    KICKERMAN360 Well-Known Member

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    In regards to the chain rubbers, have you looked into seeing if the CBR250RR MC22 chain rubber will fit? They both have "gull" swing arms and look quite similar. My MC22 is in QLD and my MC21 is in Victoria so I haven't had them side by side to check them out but maybe it's worth looking into (if they still make MC22 chain rubbers).

    I thought of a solution to the intake problem: Get a intake made up out of aluminum and use silicone hoses to connect the carbs and newly made intake together, and then just use a gasket. Fortunately I don't have to do that. If you need parts though, give Rinkya a look. They have a plethora of NSR parts. I got my intake rubber from Miyabee Plus on eBay.
     
  14. Brizfox

    Brizfox Well-Known Member Premium Member Contributing Member

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    I made a swing arm protector out of a nylon chopping board. Cut to size and the heat and bend with a hot air gun, drill and fix to original locator and fix down with counter sunk pan head bolt.
     
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  15. KICKERMAN360

    KICKERMAN360 Well-Known Member

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    So I finally took the bike for a ride, and by that I mean some drags up and down the road to run through the gears (only got to 4th though). The 929 calipers are really good and it pulls up incredible well. Quite happy with that. So now to fit the front cowl properly and make new brackets (the old ones were/are stuffed since the bike was basically totaled). Also might change to a different front fairing but sort of undecided. Regardless, need to make new brackets for that anyway.

    Then I need to re-make my speedo/battery box thingy because it's too long and I thought up a new design. And also need another wiring harness to shorten and neaten up. I have to figure out how to fit the MC18 Tyga pipes as well, but that should be easily done I think. And I need an SP Shock as well. And new tyres. But then, it should be done sans a paint job.


    IMG_1850.JPG
     
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  16. KICKERMAN360

    KICKERMAN360 Well-Known Member

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    So today I cut up some aluminium strips which I'm gonna bend into brackets for the fairing. And also thought up a new design for my front-mounted battery box that will hopefully fit better.

    My biggest problem today was trying to fit the rear tail perfectly (before I sort of just stuck it on without much thought). I got it second hand and it bolts up fine but looks... off and a little wonky. I used a measuring tape to try and double check the dimensions and from the mounting backwards, it seems to just twist out a little. Pretty obvious in the photo. So I'm thinking about getting body filler and trying to balance it out a little. Or just get a Honda RS125 tail like I wanted to originally! I know the Tyga stuff isn't as precise as Honda fairings but this one is fairly noticeably out of whack for my liking at least. Is the two part body filler (Septone Car Filler) two-pack compatible?

    IMG_1862.JPG
     
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  17. aky141

    aky141 Well-Known Member

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    Did you check the subframe was straight?
    Mine was bent
    Attacked with big screwdriver till it was back where i liked it
     
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  18. KICKERMAN360

    KICKERMAN360 Well-Known Member

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    You know, I did think of that but forgot! I'll measure that up tomorrow. I am looking into an RS125 tail and making my own sub frame as well.
     
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  19. KICKERMAN360

    KICKERMAN360 Well-Known Member

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    Gave the NSR more attention. So I made up a better battery holder/PGM mount/RegRec mount etc and it seems to fit pretty good. I need to make a more clean cut mount for the speedo unit, but otherwise fairly good result. It might be only a temporary thing too because I'm thinking of getting an MC28 speedo and wiring harness. But we'll see (most likely will happen though).

    The upper and lower were originally for the MC18 but since that is (literally) in a pile of bits now, I'm re-purposing it for the MC21. But as expected, it doesn't quite fit. But the bit that is out is the RHS mount under the exhaust. So the current plan is to cut the bottom fairing to clear the rear brake as it sort of doesn't fit very well. Sort of would prefer not to but I mucked around with it and to get both sides even (it has to clear the sidestand on the other side), it seems to be the only way.

    IMG_1866.JPG IMG_1867.JPG IMG_1868.JPG
     
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  20. KICKERMAN360

    KICKERMAN360 Well-Known Member

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    So today I worked on setting up the speedo sensor for the Trail Tech unit. I didn't realise the kit came with a magnet and a bolt with a magnet inbuilt. So I have a bolt which perfectly houses the standalone magnet and should fit well. I also have a bunch of old radiator hoses to fit the temperature sensor for the new unit.

    The body work is still a little troublesome. I haven't cut out the part for the rear brake yet but I also need to cut out some for the kickstart. I neglected to run the kickstarter though its stroke and thus there is now a chip in the body work (doh!). The body work is also a little deformed so I'll be trying to use brackets to straighten it up. The problem is some parts are gonna be tensioned up quite a bit and other bits compressed. But it should work out.
     
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