Operation: TRIPLE THREAT - 1985 NS400R Rothmans Project

[TwoStrokeNut]

Service M4.01 - Exhaust - Paint/Polish ATAC Modules...

As I approached the ATAC project, I realized it made a lot of sense to take care of the cooling system at the same time because the lower radiator hose had to be removed to take the ATAC off. But I will save the cooling cleanup for another entry, so look for that soon because it is done as well.

This is what the ATAC modules looked like before I touched them.

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Here is a before and after shot of the modules getting cleaned up.

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Here is EVERYTHING cleaned up, painted, and ready to go back on.

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Re-assembly started!

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A little further along. I didn’t bother painting the caps because they were in pretty good shape.

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Actuator installed.

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Complete with OEM exhaust.

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M4.01 Total Cost: US$0.00 [Black paint from supplies]

[silverstrom]

Finding a cover isn't difficult (I just found several online...32160-KM9-000 ). Finding it cheap is your problem.

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!!:
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.

Lack of availability will always be reflected in the price. That's obviously a problem if you are trying to do the job with only a small budget.

The link you provided is one that I saw as well and it is for multiple covers. The solution there is buy the lot and then sell what you don't need to recover your costs.

This one is only $20 https://www.jauce.com/auction/p1083207469. I buy from Jauce often. Simple and cost effective. If it shows as a blocked auction just click unblock auction and soon you'll be able to bid on it.2 days left in the auction, but it's unlikely anyone else will buy it unless they use the link I just provided.

[TwoStrokeNut]

Lack of availability will always be reflected in the price. That's obviously a problem if you are trying to do the job with only a small budget.

The link you provided is one that I saw as well and it is for multiple covers. The solution there is buy the lot and then sell what you don't need to recover your costs.

This one is only $20 https://www.jauce.com/auction/p1083207469. I buy from Jauce often. Simple and cost effective. If it shows as a blocked auction just click unblock auction and soon you'll be able to bid on it.2 days left in the auction, but it's unlikely anyone else will buy it unless they use the link I just provided.

Thanks for the Jauce suggestion... I'm already signed up and bought something else, LOL. Yes, very simple and it reminds me very much of ebay. Its interesting how you pay up front and then bid, but I understand why they do that. Lots of fees, but all small so far. Curious to see how the shipping works out. That is next after I hopefully win a second item and ship them together.

Maybe I won't had to fab up anymore parts myself!

[TwoStrokeNut]

Service M3.01 - Cooling - Clean/Refinish System Parts (Rad, Thermo housing, Etc.)...

For some reason, I don’t have an assembled BEFORE picture of the cooling system. I guess because it started out as an ATAC project and that where the camera was always pointed. So we will join the story right after I drained the radiator. Pretty nasty coolant, but it least it wasn’t straight water.

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Then it was time to pull the radiator. This will have to serve as my best BEFORE picture.

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After some clean-up, painting, and re-assembly, I ended up with all the parts ready to go back on.

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And on it went. Shroud still remained off until after I started it and checked for leaks.

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This is what I used to fill it back up.

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Shroud and bodywork back on.

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M3.01 Total Cost: US$0.00 [Paint and elbow grease from stock]

[silverstrom]

Curious to see how the shipping works out.

They have resumed shipping with EMS again, so shipping costs are now much lower.

[TwoStrokeNut]

Curious to see how the shipping works out.

They have resumed shipping with EMS again, so shipping costs are now much lower.

That's great news... I just won three small auctions and it's time to request shipping to USA.

[rz500guytexas]

Those pipes sur look like they can hold alot of unburt oil.

[TwoStrokeNut]

Those pipes sur look like they can hold alot of unburt oil.

Yeah, even the ATAC chambers can do that.

[TwoStrokeNut]

Service M6.01 - Engine Exterior - Repaint Clutch Cover...

The clutch cover was pretty nasty and you have a good view of it even with the fairing on, so I decided to address it.

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I had an NOS gasket in my spares kit just begging to be used.

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For draining the trans oil, a strategically placed piece of tape and some foam to hold the carb drain hoses out of the way kept oil from getting all over the exhaust.

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Here is the cover with a fresh coat of paint. Not perfect, but it will do. It has some dust on it after sitting for a week drying in my shop.

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The kickstarter gasket got replaced and I had to buy one. They must be used on other bikes because it was readily available and inexpensive.

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I used my high temperature release agent on the gasket.

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And back on the cover went.

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This is what I used to fill the tranny.

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And here is an overall shot of the right side. This also serves to better show the finished radiator.

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M6.01 Total Cost: US$8.00 [Cover gasket from spares; Seal purchased, paint from supplies]

[TwoStrokeNut]

Service E4.01 - Lights - Get Neutral Indicator Working...

Pulling the clutch cover off for a repaint gave me the perfect opportunity to troubleshoot the intermittent neutral light problem.

I had a spare neutral switched pulled from one of my extra engine cases ready to go, but the culprit was evident as soon as the cover was pulled.

The female bullet connector that snaps on to the switch was plugged with… something. How it got that way, I don’t know, because the inside of the clutch chamber was virtually spotless. I’m surprised I even saw the light flash on at all… it must have been occasionally hitting the switch.

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After working on it, I picked all the grunge out. Whatever it was, it was pretty hard. Anyway, it again snapped onto the switch.

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With the cover still off, I tested the switch repeatedly and it worked flawlessly.

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It’s nice to see that neutral light again!

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E4.01 Total Cost: US$0.00 [Nothing needed]

[Smoker]

Came back to look at some of your decal work. I remember how you did it- I just wanted to get juiced up for doing some decal work myself.

How's the bike doing? Miss your great, informative posts.