Operation: TRIPLE THREAT - 1985 NS400R Rothmans Project
Moderator: rztom
- TwoStrokeNut
- Posts: 585
- Joined: Tue Nov 20, 2012 5:12 pm
- Location: Florida,USA
Re: Operation: TRIPLE THREAT - 1985 NS400R Rothmans Project
Service C6.05 - Seat - Add tie-down loops...
Although my seat came with the mounting brackets, the cargo tie-down straps were missing. I haven’t seen any for sale either so I decided to take a shot at making my own. This is something that I don’t care if it is 100% OEM, I simply don’t want it to look like something is missing.
I had some SS tubing on hand and I figured one size would work out nicely.
Picture 960
To match the cutouts in the solo tail perfectly, I marked exactly where they needed to be on the seat.
Picture 961
I then went to work with some electrical wire and once I figured out the shape , I tried copper brake tubing (because it still bends easily) and this allowed me to flatten the ends so it could be mounted.
Picture 962
Here was the first attempt. I was happy with it and decided to do the final version in stainless tubing
Picture 963
After bending both loops, my hands were crying, but I got through it.
Picture 964
Picture 965
Picture 966
This better explains my pointers on the seat.
Picture 967
Picture 968
Picture 969
Here are some shots from underneath to show how they mount.
Picture 970
Picture 971
Here is the progression of samples to get to the end result.
Picture 972
And some overall shots of the finished tie-down loops.
Picture 973
Picture 974
I don’t ever intend to use them, so they are essential just for show. But they seem strong enough to use should I ever need to.
C6.05Total Cost: US$0.00 [Raw tubing US$6.00]
Although my seat came with the mounting brackets, the cargo tie-down straps were missing. I haven’t seen any for sale either so I decided to take a shot at making my own. This is something that I don’t care if it is 100% OEM, I simply don’t want it to look like something is missing.
I had some SS tubing on hand and I figured one size would work out nicely.
Picture 960
To match the cutouts in the solo tail perfectly, I marked exactly where they needed to be on the seat.
Picture 961
I then went to work with some electrical wire and once I figured out the shape , I tried copper brake tubing (because it still bends easily) and this allowed me to flatten the ends so it could be mounted.
Picture 962
Here was the first attempt. I was happy with it and decided to do the final version in stainless tubing
Picture 963
After bending both loops, my hands were crying, but I got through it.
Picture 964
Picture 965
Picture 966
This better explains my pointers on the seat.
Picture 967
Picture 968
Picture 969
Here are some shots from underneath to show how they mount.
Picture 970
Picture 971
Here is the progression of samples to get to the end result.
Picture 972
And some overall shots of the finished tie-down loops.
Picture 973
Picture 974
I don’t ever intend to use them, so they are essential just for show. But they seem strong enough to use should I ever need to.
C6.05Total Cost: US$0.00 [Raw tubing US$6.00]
Project bike links: NS400R - TRIPLE THREAT // RZ500 - MOSQUITO CONTROL BIKE // RZ350 - REVIVAL
'72 H1-500/'75 H1-500/'85 RZ350/'85 NS400R/'01 DR650/'07 FJR1300/'18 Tiger 1200
'72 H1-500/'75 H1-500/'85 RZ350/'85 NS400R/'01 DR650/'07 FJR1300/'18 Tiger 1200
Re: Operation: TRIPLE THREAT - 1985 NS400R Rothmans Project
Great post. I forgot how awesome your threads are.
Helped me get through many painful days.
Thanks, again!
Helped me get through many painful days.
Thanks, again!
- TwoStrokeNut
- Posts: 585
- Joined: Tue Nov 20, 2012 5:12 pm
- Location: Florida,USA
Re: Operation: TRIPLE THREAT - 1985 NS400R Rothmans Project
Glad I could help in some small way.
Thanks so much for following along!
Thanks so much for following along!
Project bike links: NS400R - TRIPLE THREAT // RZ500 - MOSQUITO CONTROL BIKE // RZ350 - REVIVAL
'72 H1-500/'75 H1-500/'85 RZ350/'85 NS400R/'01 DR650/'07 FJR1300/'18 Tiger 1200
'72 H1-500/'75 H1-500/'85 RZ350/'85 NS400R/'01 DR650/'07 FJR1300/'18 Tiger 1200
- TwoStrokeNut
- Posts: 585
- Joined: Tue Nov 20, 2012 5:12 pm
- Location: Florida,USA
Re: Operation: TRIPLE THREAT - 1985 NS400R Rothmans Project
Service C6.04- Seat - Add passenger strap...
My OEM seat needed a strap and I wanted a replacement seat cover anyway, so I ordered a kit that had both the cover and strap kit. Installing the seat cover will have to wait until another day. With the old cover on yet, I’m going to pay attention to whether the solo tail chaffs on the seat.
Picture 975
I wasn’t happy with the buckles, so I made two out of some thin stainless strap.
Picture 976
Finished strap.
Picture 977
And finally installed.
Picture 978
Picture 979
C6.04 Total Cost: US$57.00 [Seat cover kit and shipping]
My OEM seat needed a strap and I wanted a replacement seat cover anyway, so I ordered a kit that had both the cover and strap kit. Installing the seat cover will have to wait until another day. With the old cover on yet, I’m going to pay attention to whether the solo tail chaffs on the seat.
Picture 975
I wasn’t happy with the buckles, so I made two out of some thin stainless strap.
Picture 976
Finished strap.
Picture 977
And finally installed.
Picture 978
Picture 979
C6.04 Total Cost: US$57.00 [Seat cover kit and shipping]
Project bike links: NS400R - TRIPLE THREAT // RZ500 - MOSQUITO CONTROL BIKE // RZ350 - REVIVAL
'72 H1-500/'75 H1-500/'85 RZ350/'85 NS400R/'01 DR650/'07 FJR1300/'18 Tiger 1200
'72 H1-500/'75 H1-500/'85 RZ350/'85 NS400R/'01 DR650/'07 FJR1300/'18 Tiger 1200
- TwoStrokeNut
- Posts: 585
- Joined: Tue Nov 20, 2012 5:12 pm
- Location: Florida,USA
Re: Operation: TRIPLE THREAT - 1985 NS400R Rothmans Project
Service C5.10 - Frame - Find and Install OEM Rear Fender...
The seller that had the OEM seat eventually listed a rear fender for sale, so I snapped it up.
Picture 980
Picture 981
Picture 982
It came with the supports for the turn signals.
Picture 983
With a little protectant applied, it looked nearly new.
Picture 984
Picture 985
Here is a comparison of the full and chopped fender.
Picture 986
Old fender removed.
Picture 987
Now that there is something hanging down there, I purchased a license plate bracket. Bracket and turn signals went on.
Picture 988
And a final shot with a plate on.
Picture 989
C5.10Total Cost: US$77.00 [Fender and shipping]
The seller that had the OEM seat eventually listed a rear fender for sale, so I snapped it up.
Picture 980
Picture 981
Picture 982
It came with the supports for the turn signals.
Picture 983
With a little protectant applied, it looked nearly new.
Picture 984
Picture 985
Here is a comparison of the full and chopped fender.
Picture 986
Old fender removed.
Picture 987
Now that there is something hanging down there, I purchased a license plate bracket. Bracket and turn signals went on.
Picture 988
And a final shot with a plate on.
Picture 989
C5.10Total Cost: US$77.00 [Fender and shipping]
Project bike links: NS400R - TRIPLE THREAT // RZ500 - MOSQUITO CONTROL BIKE // RZ350 - REVIVAL
'72 H1-500/'75 H1-500/'85 RZ350/'85 NS400R/'01 DR650/'07 FJR1300/'18 Tiger 1200
'72 H1-500/'75 H1-500/'85 RZ350/'85 NS400R/'01 DR650/'07 FJR1300/'18 Tiger 1200
- TwoStrokeNut
- Posts: 585
- Joined: Tue Nov 20, 2012 5:12 pm
- Location: Florida,USA
Re: Operation: TRIPLE THREAT - 1985 NS400R Rothmans Project
Service C5.09 - Frame - Find and Install Toolbox Lid...
When I bought the rear fender, the seller had a toolbox too. I didn’t need another toolbox, but I was really after the lid. Here’s what was sent.
Picture 990
Picture 991
A little cleanup and it was looking better.
Picture 992
Picture 993
And installed.
Picture 994
Picture 995
Picture 996
C5.09 Total Cost: US$42.00 [Toolbox and shipping]
When I bought the rear fender, the seller had a toolbox too. I didn’t need another toolbox, but I was really after the lid. Here’s what was sent.
Picture 990
Picture 991
A little cleanup and it was looking better.
Picture 992
Picture 993
And installed.
Picture 994
Picture 995
Picture 996
C5.09 Total Cost: US$42.00 [Toolbox and shipping]
Project bike links: NS400R - TRIPLE THREAT // RZ500 - MOSQUITO CONTROL BIKE // RZ350 - REVIVAL
'72 H1-500/'75 H1-500/'85 RZ350/'85 NS400R/'01 DR650/'07 FJR1300/'18 Tiger 1200
'72 H1-500/'75 H1-500/'85 RZ350/'85 NS400R/'01 DR650/'07 FJR1300/'18 Tiger 1200
- TwoStrokeNut
- Posts: 585
- Joined: Tue Nov 20, 2012 5:12 pm
- Location: Florida,USA
Re: Operation: TRIPLE THREAT - 1985 NS400R Rothmans Project
Service E4.04 - Lights - Replace Tail Light...
Here is an early shot of the old cracked and dingy tail light.
Picture 015
Someone on ebay in the States had a decent light for sale not long after I purchased the bike, so I snapped it up. And now I finally had the time to do something with it.
Here it is installed. It’s not perfect with a groove worn in the upper left corner where a mal-adjusted tail piece likely was rubbing it, but remember what I always say about this bike… I’m not striving for perfection!
Picture 997
Picture 998
E4.04 Total Cost: US$43.00 [Light and shipping]
Here is an early shot of the old cracked and dingy tail light.
Picture 015
Someone on ebay in the States had a decent light for sale not long after I purchased the bike, so I snapped it up. And now I finally had the time to do something with it.
Here it is installed. It’s not perfect with a groove worn in the upper left corner where a mal-adjusted tail piece likely was rubbing it, but remember what I always say about this bike… I’m not striving for perfection!
Picture 997
Picture 998
E4.04 Total Cost: US$43.00 [Light and shipping]
Project bike links: NS400R - TRIPLE THREAT // RZ500 - MOSQUITO CONTROL BIKE // RZ350 - REVIVAL
'72 H1-500/'75 H1-500/'85 RZ350/'85 NS400R/'01 DR650/'07 FJR1300/'18 Tiger 1200
'72 H1-500/'75 H1-500/'85 RZ350/'85 NS400R/'01 DR650/'07 FJR1300/'18 Tiger 1200
-
- - - - - -
- Posts: 609
- Joined: Thu May 24, 2018 5:22 pm
Re: Operation: TRIPLE THREAT - 1985 NS400R Rothmans Project
Hey, it looks like you changed to a more, uh, aggressive rear tire.
- TwoStrokeNut
- Posts: 585
- Joined: Tue Nov 20, 2012 5:12 pm
- Location: Florida,USA
Re: Operation: TRIPLE THREAT - 1985 NS400R Rothmans Project
Yeah, that tire was on there when I bought the bike. Why? I'll never know. It was on the wider CBR600 rim. Luckily, it's a perfect fit for my DR650 dualsport bike, so it won't go to waste!lost1750GTV wrote: ↑Thu Apr 20, 2023 5:49 pm Hey, it looks like you changed to a more, uh, aggressive rear tire.
Project bike links: NS400R - TRIPLE THREAT // RZ500 - MOSQUITO CONTROL BIKE // RZ350 - REVIVAL
'72 H1-500/'75 H1-500/'85 RZ350/'85 NS400R/'01 DR650/'07 FJR1300/'18 Tiger 1200
'72 H1-500/'75 H1-500/'85 RZ350/'85 NS400R/'01 DR650/'07 FJR1300/'18 Tiger 1200
- TwoStrokeNut
- Posts: 585
- Joined: Tue Nov 20, 2012 5:12 pm
- Location: Florida,USA
Re: Operation: TRIPLE THREAT - 1985 NS400R Rothmans Project
Service C1.15 - Body - Find and Install Pattern Mirrors...
I already had an everyday riding solution, but the aftermarket set of mirrors I installed before were far from OEM looking. So when these popped up, I snapped them up. Since I don’t have a record of where I bought them (it was months ago now) it must have been an individual on a forum selling them. I don’t even have record of the price I paid, but I believe it was around $50 or so.
Picture 999
Picture 1000
If you notice, there is a slight difference in where the retaining groove is machined in the pivot pin, so I needed to remove the pins and do a little turning on the lathe. OEM is on the left, Pattern on the right.
Picture 1001
With that mod behind me, on they went.
Picture 1002
Picture 1003
If only I had found these before I painted those RC30 white mirrors black. Oh well.
Picture 1004
C1.15 Total Cost: US$60.00 [Mirrors and shipping]
I already had an everyday riding solution, but the aftermarket set of mirrors I installed before were far from OEM looking. So when these popped up, I snapped them up. Since I don’t have a record of where I bought them (it was months ago now) it must have been an individual on a forum selling them. I don’t even have record of the price I paid, but I believe it was around $50 or so.
Picture 999
Picture 1000
If you notice, there is a slight difference in where the retaining groove is machined in the pivot pin, so I needed to remove the pins and do a little turning on the lathe. OEM is on the left, Pattern on the right.
Picture 1001
With that mod behind me, on they went.
Picture 1002
Picture 1003
If only I had found these before I painted those RC30 white mirrors black. Oh well.
Picture 1004
C1.15 Total Cost: US$60.00 [Mirrors and shipping]
Project bike links: NS400R - TRIPLE THREAT // RZ500 - MOSQUITO CONTROL BIKE // RZ350 - REVIVAL
'72 H1-500/'75 H1-500/'85 RZ350/'85 NS400R/'01 DR650/'07 FJR1300/'18 Tiger 1200
'72 H1-500/'75 H1-500/'85 RZ350/'85 NS400R/'01 DR650/'07 FJR1300/'18 Tiger 1200
- TwoStrokeNut
- Posts: 585
- Joined: Tue Nov 20, 2012 5:12 pm
- Location: Florida,USA
Re: Operation: TRIPLE THREAT - 1985 NS400R Rothmans Project
Service E6.01 - Wiring - Find and Install connector cover...
I have been searching for a reasonable priced connector cover for some time so I had a matching set. No luck. I simply got to the point I was sick of looking for it, so I decided to make something from nothing. Here is the little cover I’m talking about. It hides the connector junctions on each side of the engine.
This is the part I’m trying to make a functional replacement for.
Picture 1005
Picture 1006
I don’t really care if it looks perfect, I just want it to hide those dang connectors. I figured if I spend time to build my own, one is sure to pop up on ebay for 5 bucks in a week or two, right? LOL
I looked around the shop for scraps of black plastic that might work and this is what I found.
Picture 1007
Picture 1008
What I ended up with is this.
Picture 1009
Picture 1010
And this is what it looks like installed. I also will give you a view of the other proper one on the other side.
Picture 1011
Picture 1012
Okay you NS400R parts guys, you can list that connector cover for sale now at a steal of a price! LOL
I’ll list this one as a Part 1, because I’m sure there will be a Part 2 followup.
E6.01 Total Cost: US$0.00 [Parts for inventory]
I have been searching for a reasonable priced connector cover for some time so I had a matching set. No luck. I simply got to the point I was sick of looking for it, so I decided to make something from nothing. Here is the little cover I’m talking about. It hides the connector junctions on each side of the engine.
This is the part I’m trying to make a functional replacement for.
Picture 1005
Picture 1006
I don’t really care if it looks perfect, I just want it to hide those dang connectors. I figured if I spend time to build my own, one is sure to pop up on ebay for 5 bucks in a week or two, right? LOL
I looked around the shop for scraps of black plastic that might work and this is what I found.
Picture 1007
Picture 1008
What I ended up with is this.
Picture 1009
Picture 1010
And this is what it looks like installed. I also will give you a view of the other proper one on the other side.
Picture 1011
Picture 1012
Okay you NS400R parts guys, you can list that connector cover for sale now at a steal of a price! LOL
I’ll list this one as a Part 1, because I’m sure there will be a Part 2 followup.
E6.01 Total Cost: US$0.00 [Parts for inventory]
Project bike links: NS400R - TRIPLE THREAT // RZ500 - MOSQUITO CONTROL BIKE // RZ350 - REVIVAL
'72 H1-500/'75 H1-500/'85 RZ350/'85 NS400R/'01 DR650/'07 FJR1300/'18 Tiger 1200
'72 H1-500/'75 H1-500/'85 RZ350/'85 NS400R/'01 DR650/'07 FJR1300/'18 Tiger 1200
-
- - - - - -
- Posts: 3241
- Joined: Sat Feb 04, 2012 7:36 am
Re: Operation: TRIPLE THREAT - 1985 NS400R Rothmans Project
Finding a cover isn't difficult (I just found several online...32160-KM9-000 ). Finding it cheap is your problem.
Re: Operation: TRIPLE THREAT - 1985 NS400R Rothmans Project
Frugal is a better word and what I mean by that. Try looking for NC11 parts. They are compatible with the NC19
1985 RG500(Walter Wolfe)
1984 IT490
1985 RZV500R
1997 VFR750
1992 FZR1000
RGV500
TZR500
TZR350
1990 RZ350
1971 Porsche911S
1984 IT490
1985 RZV500R
1997 VFR750
1992 FZR1000
RGV500
TZR500
TZR350
1990 RZ350
1971 Porsche911S
- TwoStrokeNut
- Posts: 585
- Joined: Tue Nov 20, 2012 5:12 pm
- Location: Florida,USA
Re: Operation: TRIPLE THREAT - 1985 NS400R Rothmans Project
The only actual one I found for sale last time I looked is this one with other parts I don't need for USD 140 delivered... don't need it that badly!!:silverstrom wrote: ↑Thu Apr 27, 2023 12:30 pm Finding a cover isn't difficult (I just found several online...32160-KM9-000 ). Finding it cheap is your problem.
https://www.ebay.com/itm/233706806366
It would be difficult for me to spend more than $30-40 on this small piece of plastic that is essentially cosmetic.
If you have a source, let me know.
Project bike links: NS400R - TRIPLE THREAT // RZ500 - MOSQUITO CONTROL BIKE // RZ350 - REVIVAL
'72 H1-500/'75 H1-500/'85 RZ350/'85 NS400R/'01 DR650/'07 FJR1300/'18 Tiger 1200
'72 H1-500/'75 H1-500/'85 RZ350/'85 NS400R/'01 DR650/'07 FJR1300/'18 Tiger 1200
- TwoStrokeNut
- Posts: 585
- Joined: Tue Nov 20, 2012 5:12 pm
- Location: Florida,USA
Re: Operation: TRIPLE THREAT - 1985 NS400R Rothmans Project
I think I picked up a few NS250 parts along the way for this project. Often times I forget to search on it though... thanks for the reminder!!
Project bike links: NS400R - TRIPLE THREAT // RZ500 - MOSQUITO CONTROL BIKE // RZ350 - REVIVAL
'72 H1-500/'75 H1-500/'85 RZ350/'85 NS400R/'01 DR650/'07 FJR1300/'18 Tiger 1200
'72 H1-500/'75 H1-500/'85 RZ350/'85 NS400R/'01 DR650/'07 FJR1300/'18 Tiger 1200