DIY Yamaha tire hugger modification and install

[headshrink]

This is my version of the modified hugger from the Yamaha group-buy. It's from a bike that isn’t being sold in the US, hence the group-buy to make importing it cost-effective. Here's a link to that original thread, with several other solutions buried within from other Ninjetters:

http://www.ninjette.org/forums/showthread.php?t=78803

First I had to remove the left passenger peg bracket, and muffler, to gain adequate access to fit the hugger.

Next I trimmed down the parts of the hugger that interfered with parts on the Ninjette.

This needs to be trimmed to allow clearance for the rear break.





The vertical stiffener on the inside was also shaved down to maintain clearance with the rear brake.



Some material was trimmed from the side to make room for the stock rear brake line. Those with aftermarket SS brake lines won’t have to worry about this part.



This square is trimmed to create clearance for the tab on the left swing arm that holds the inside edge of the stock chain guard.



These are cut to cleanup the design and fit a bit.




Next I fabricated some brackets out of aluminum sheet metal (I don’t recall the gauge used).



This is the bracket for the hugger’s right side mounting bolt. I used a speed-nut clip for ease of use, and to maintain a minimal profile where space is tight. Note: The pictured bracket is actually the first prototype. I remade it with a little different angle so it would reach a little further back.



You can’t see it in the picture, but this [first] bracket is held in place by the bold that holds down the brake hose guide. I just loosened the bolt, and slid the bracket under it, and it holds nicely, without the need to tighten it back down. A slot in the bracket, rather than a hole, allows me to do this without removing the bolt all the way.



Here is the final bracket design painted, and installed.



Right side being bolted up to test fit before the muffler was put back on.



Although the hugger’s rear mounting hole fits fine with the original Ninjette design, a bracket was required for the front mounting bolt.





Again a speed-nut tab was used. I really like them 



Brackets being spray painted.



And here are the final results.





The clearance between the right side and my AREA P isn’t great… in fact it touches, but hopefully this wont cause a problem, as it only rubs on the APEA P mounting bracket. I may trim the hugger down a little more later, if this proves to be a problem.



Fortunately the muffler is high enough that I can easily access the right mounting bolt with a box wrench for easy hugger removal.



EDIT: I went back and trimmed the right ride a bit. This seemed to help the fitment a bit.




If you have done this mod/install, please post your pictures below too. I’m sure pictures of other solutions will be helpful to others who want to do this project.

[Scattcatt]

Awesome write up! That's a ton of work you had to put into that hugger! I hope my Honda CBR250 hugger doesn't require THAT much modding... If it does though, you'll certainly be my inspiration

[headshrink]

Originally Posted by Scattcatt

Awesome write up! That's a ton of work you had to put into that hugger! I hope my Honda CBR250 hugger doesn't require THAT much modding... If it does though, you'll certainly be my inspiration

Thanks. It was a little more than I thought, and still isn't perfect, but it's a cheap solution.

I've been dying to see how the CBR250 hugger fits.... hurry up! ;p

[Scattcatt]

Originally Posted by headshrink

Thanks. It was a little more than I thought, and still isn't perfect, but it's a cheap solution.

I've been dying to see how the CBR250 hugger fits.... hurry up! ;p

Isn't there someone who already has the CBR250 hugger installed? I thought so! I'll see if I can dig that thread out. I'm waiting for it to get shipped here!!! Freaking Ride Now, they're always wrong on their days they tell me my stuff will get in. I deal with them as little as I can now, especially considering my brother works for Cycle Gear Anyway, should be here by like Tuesday.... I hope..... I REALLY hope... And I'll get it installed whatever day I get it I'm sure too. If it requires a lot of work I'll make a DIY like you did if one doesn't exist already

[Scattcatt]

Here ya go, a more-or-less DIY, just not quite as easy to follow as yours (though it's still plenty easy to understand) http://www.ninjette.org/forums/showt...cbr250r+hugger

They look pretty similar! At first glance I thought yours was from the CBR

[headshrink]

Originally Posted by Scattcatt

Here ya go, a more-or-less DIY, just not quite as easy to follow as yours (though it's still plenty easy to understand) http://www.ninjette.org/forums/showt...cbr250r+hugger

They look pretty similar! At first glance I thought yours was from the CBR

Those are some good comparison shots, thanks!

[Scattcatt]

Any time! Have you tested your undertail clearance? There's some fear stated in that thread about the possibility of the hugger hitting under high suspension compression.

[headshrink]

Originally Posted by Scattcatt

Any time! Have you tested your undertail clearance? There's some fear stated in that thread about the possibility of the hugger hitting under high suspension compression.

It never occured to me. I did one test run, but there weren't any really rough spots. I thought it may vibrate a bit up front/under tail, but it SEEMED fine.

[Scattcatt]

You can always go out and just bounce on the tail and see how close things get that's how I'm going to test it. I might even set the preload back to 1 just to see (it's on 5 right now... With all my gear and stuff for class I'm probably around 250 pounds so I keep it on the stiffest setting)

[Alex]

/linked from main DIY

[Scattcatt]

So just found out today that my hugger was backordered... No clue when it will be in, I was told last week... Then today... Now whenever. This sucks!

[MikeBudd]

I can't believe I missed out on this gb... I've always wanted that hugger

Nice write up man! Hopefully I will use this when I buy it (eventually...)

[headshrink]

Thanks. I'm going to trim down the right side a touch more the next time I have it off the bike.

[headshrink]

^bump^

I just added an edit at the bottom of the OP. I re-trimmed the right a bit.

[C L]

Gonna work on this this weekend

[wayanlam]

my minion of huggers that i shipped over are being put through their paces and getting installed nicely

great job!

[C L]

Couldn't wait for the weekend and started just now...

How does your right side sit so flush like that with the brake hose guide there?



I haven't made the bracket to bolt it on yet but mine sticks out way far because the guiding bracket is in the way.


This is with the other side bolted on

Does it matter if the brake line guiding bracket is removed? Mine sits perfectly flush without the bracket there (it pushes the hose under the assembly though).

[thebozenator]

I removed the bracket when i did mine. (http://www.ninjette.org/forums/showt...rocket&page=16)

The brake line will still be secure without it. If you make a custom bracket it should straighten out the end of the right side.

[thebozenator]

btw, great idea using the speed-nut clips. what kind of paint did you use? Ive been meaning to paint my brackets but i am not sure what would be the most durable.

[headshrink]

Originally Posted by thebozenator

btw, great idea using the speed-nut clips. what kind of paint did you use? Ive been meaning to paint my brackets but i am not sure what would be the most durable.

I used some rustoleum I had sitting around. I origionally got it to spray paint some pipe.

[headshrink]

Originally Posted by C L

How does your right side sit so flush like that with the brake hose guide there?

Mine did stick out a little, which is why I trimmed it down this weekend. This helped a lot. When I installed my area P, I hammered the bracket in a little for clearance. This helped a little for this mod too. If I had my pipe off right now, I would probably just remove the break line bracket altogether. I still may do that when my wheel comes off next.

[C L]

Ta-daa!!!



Ended up taking the brake line bracket off and now it sits perfectly flush

[headshrink]

Nicely done.