Ok, 2nd DIY is under way. :)
The 2nd post is reserved for the final part which I can't do until I get the fairings back on which will probably be a week or so as all mods are on hold until my replacement tail tidy arrives.

Hopefully the photo's are a better quality and it may seem like I'm going overkill on the photos but I'm trying to provide enough shots/angles of the install as there is some uncertainty if this will fit on non FI 250r's

As in my last DIY, my start point is with all fairings off and the bike on the rear stand so I won't be covering that, but kkim has that already covered ;)

Just to say in bold.....

YOU WANT THE BIKE ON A REAR STAND WHEN DOING THIS - THE KICKSTAND IS NOT ENOUGH

Tools you'll need;
set of metric allen keys
socket set to include 17mm, 14mm and 15mm A/F socket and wrench
14mm and 17mm spanner
torque wrench to be used at 40NM
soft headed hammer

So what comes in the box - it's all well packaged and the parts are made to a very high quality finish. They are very solid and sturdy too. Very Impressive. You can believe the hype "the only insurance approved crash protectors on the market" after seeing these up close.

http://www.ninjette.org/forums/picture.php?albumid=59&pictureid=609

and the instructions

http://www.ninjette.org/forums/picture.php?albumid=59&pictureid=610
http://www.ninjette.org/forums/picture.php?albumid=59&pictureid=611

Now the instructions don't mention this step but I would recommend that you prepare a jack to apply light pressure from below. This will help to support the bike and stop it dropping when your knocking out the engine mount bolt. I didn't do this at first and even though I was really careful, when the original engine mount bolt was almost all the way through, the bike twisted and dropped and I wasn't able to knock the replacement bar through anymore as the holes no longer lined up.
If you dont have a jack you'll at least want to make sure that the bike is on level ground. Mine was not and I attribute the little mishap to this. But even so, if I was to do it again, I would use a jack for support.
You'll want something softer in between the jack and bike - I used an old bit of mdf that I had floating around

http://www.ninjette.org/forums/picture.php?albumid=59&pictureid=619

Let's have a look where on the bike they will be mounting... as we'll need to make space for the bracket.
need to work on the left side first so lets have a look

http://www.ninjette.org/forums/picture.php?albumid=59&pictureid=612

You should be able see a familiar shape, this is where the large flat bracket will be mounted and we will need to remove 3 bolts to provide mount points for the R&G bracket
Note that the top 2 are obscured by the rectifier

http://www.ninjette.org/forums/picture.php?albumid=59&pictureid=613

the bottom of the 3 is the engine mount bolt, this goes all the way through to the other side.

http://www.ninjette.org/forums/picture.php?albumid=59&pictureid=614

The right side contains the nut for this bolt. It's on fairly tight but it's easy enough to remove with a normal socket wrench

http://www.ninjette.org/forums/picture.php?albumid=59&pictureid=615

and it will look like this

http://www.ninjette.org/forums/picture.php?albumid=59&pictureid=616

Now were ready to gently knock though the original engine mount bolt with the replacement, using a soft headed mallet of some kind,
YOU HAVE TO PREPARE/MOVE THE HOSE SO THAT IT'S NOT IN THE WAY OF THE BOLT COMING OUT

http://www.ninjette.org/forums/picture.php?albumid=59&pictureid=617

SEE HOW CLOSE THE HOSE IS, IT WILL STOP THE BOLT COMING OUT IF YOU DO NOT MOVE IT OUT THE WAY

http://www.ninjette.org/forums/picture.php?albumid=59&pictureid=618

It should look like this when the original engine mount bolt is out and the R&G Racing bar has replaced it

http://www.ninjette.org/forums/picture.php?albumid=59&pictureid=621

Need to move that rectifier now, but we only need to undo the 2 bolts securing it and then dangle it somewhere outta the way. Should look like this.

http://www.ninjette.org/forums/picture.php?albumid=59&pictureid=622

At last! We have access to the other bolts so we can mount the bracket. So let's remove them, They're on fairly tight but nothing to worry about.
They also have nuts on the other side, you can reach round like I did in the photos below and remove them. I didn't have to (maybe I got lucky), but I did not need to hold these nuts with a spanner to undo the bolts. You'll want to keep the nuts for use later on.

http://www.ninjette.org/forums/picture.php?albumid=59&pictureid=623

http://www.ninjette.org/forums/picture.php?albumid=59&pictureid=624

With the bolts removed we can finally mount the bracket so let's assemble it.
For the left side you want the SHORTER cylinder and flat bracket WITHOUT the cut in the back and 3 of the M10x30mm long cap head bolts

http://www.ninjette.org/forums/picture.php?albumid=59&pictureid=625

It will only fit one way, and the fit is superb, as good a quality as the woodcraft clipons. Use loctite on the 3 bolts and secure. I did these up as tight as was physically possible with the allen key

http://www.ninjette.org/forums/picture.php?albumid=59&pictureid=626

notice the angled ending, this is what will poke through the fairing in a very well engineered fit

http://www.ninjette.org/forums/picture.php?albumid=59&pictureid=627

this is where it will be going on the bike

http://www.ninjette.org/forums/picture.php?albumid=59&pictureid=628

http://www.ninjette.org/forums/picture.php?albumid=59&pictureid=629

So let's prepare the bolts and the left assembly, you'll need 2 of the M10x60mm long cap head bolts to go into the top 2 holes (the bottom hole is for the engine mount bar)

http://www.ninjette.org/forums/picture.php?albumid=59&pictureid=630

Need to put the THINNER spacers on these bolts next

http://www.ninjette.org/forums/picture.php?albumid=59&pictureid=632

http://www.ninjette.org/forums/picture.php?albumid=59&pictureid=631

http://www.ninjette.org/forums/picture.php?albumid=59&pictureid=633

The unit can now be slot into place like so, lining up the 2 bolts with the freed up mount points and the single hole with the engine bar

http://www.ninjette.org/forums/picture.php?albumid=59&pictureid=634

http://www.ninjette.org/forums/picture.php?albumid=59&pictureid=635

and we'll need the 2 nuts saved from earlier plus some loctite to secure the top 2 bolts. Again, I just did them up as tight as I possibly could with the allen key.

http://www.ninjette.org/forums/picture.php?albumid=59&pictureid=636

Now we've finished with those 2 bolts we can re-install the rectifier, but you'll find that the original bolts are not long enough and the rectifier does not sit flush with it's mounting plate any more.
So we need to use the other 2 fatter spacers and the 2 M6x40mm long button head bolts. (Note the original bolts at the top of the pic)

http://www.ninjette.org/forums/picture.php?albumid=59&pictureid=637

http://www.ninjette.org/forums/picture.php?albumid=59&pictureid=638

Should look like this

http://www.ninjette.org/forums/picture.php?albumid=59&pictureid=640

http://www.ninjette.org/forums/picture.php?albumid=59&pictureid=641

For now we're done on the left, Lets get started on the right side. Removing the top 2 bolts is the same as the left side so no need to cover that again, just keep the nuts ;)

http://www.ninjette.org/forums/picture.php?albumid=59&pictureid=642

and we have the longer cylinder + flat bracket with the cut-out in it to work with which is assembled in the same way too - just without the spacers

http://www.ninjette.org/forums/picture.php?albumid=59&pictureid=643

http://www.ninjette.org/forums/picture.php?albumid=59&pictureid=644

and the mounting of this completed assembly is the same as the left too, woohoo! this DIY is getting a bit easier ;)

http://www.ninjette.org/forums/picture.php?albumid=59&pictureid=645

http://www.ninjette.org/forums/picture.php?albumid=59&pictureid=646

Next we use the 2 self locking nuts provided and fasten them to the engine mount bar (the long bar going through the hole at the bottom) and do these up loosely for now with the thread sticking out the same amount on both sides.

And I've just loosely put the aero shaped sliders on the end for now so I don't loose any parts.
There are some nice slick end covers for the aero sliders so they won't show the hollow or nuts, I just left them till I'm finished.
Torquing and finishing the DIY to follow next week

http://www.ninjette.org/forums/picture.php?albumid=59&pictureid=647

http://www.ninjette.org/forums/picture.php?albumid=59&pictureid=648

Time to get this finished!

so with the left and right side mounted (without the sliders attached to the end)
tighten up the last of the 3 (the bottom one) mount point to 40 NM with a torque wrench

http://www.ninjette.org/forums/picture.php?albumid=59&pictureid=646

With that done, we gotta mount the fairings. Just reverse the order in which you took them off. The nice thing to note is that even though its a precise fit, these crash protectors do not interfere with the install/removal of the fairings. Should look like this

http://www.ninjette.org/forums/picture.php?albumid=59&pictureid=776

http://www.ninjette.org/forums/picture.php?albumid=59&pictureid=775

Now it's time to mount the sliders using the last bolt and washer supplied. Use the torque wrench and no more than 40NM (orientate the slider so that the fatter end is toward the front of the bike)

http://www.ninjette.org/forums/picture.php?albumid=59&pictureid=777

http://www.ninjette.org/forums/picture.php?albumid=59&pictureid=778

Pop in the cover

http://www.ninjette.org/forums/picture.php?albumid=59&pictureid=779

and that's it :)

rear view

http://www.ninjette.org/forums/picture.php?albumid=59&pictureid=780

front view

http://www.ninjette.org/forums/picture.php?albumid=59&pictureid=781

Greg... excellent, excellent DIY, so far. :)

Looks like I've got some competition to "kick it up a notch". Hmmm... wonder if I should include DIYs girls when I do mine from now on. :D

I'm sure people will love that you are taking the time to do these. (I know how much of a PITA it is to snap pics along the way) Good job on giving back to your fellow forum members. :thumbup:

Nice work Greg - it is great to have DIY's like this for future projects.

I love these DIYs. i'm new to biking and these help so much in learning about the 250r. Keep up the good work! :thumbup:

Greg... excellent, excellent DIY, so far. :)

Looks like I've got some competition to "kick it up a notch". Hmmm... wonder if I should include DIYs girls when I do mine from now on. :D

I'm sure people will love that you are taking the time to do these. (I know how much of a PITA it is to snap pics along the way) Good job on giving back to your fellow forum members. :thumbup:

No no no :eek: No competition, I'm just following the excellent templates set out by your goodself :thumbup:

Just trying to put a little bit back on some products that the majority may be unfamiliar with :)

Don't hold back on the DIY girls though ;)

and yeah PITA is the phrase for it. Just uploading the pics and writing the DIY has taken twice as long as the job itself lol.
Feels good to do it though. Pay it forward my man! :)

Pay it forward my man! :)
The quality of your DIYs are only eclipsed by your understanding of what truly makes the world go round.

Thanks for contributing. :thumbup:

Thanks for the great writeup.

aww.. *group hug* :) lol

Greg are you doing a DIY on the mirrors? and are those the ebay universal ones and did you modify the stalk any or did you just mount them as is? looks great man! good job

Very nice DIY. Thanks for posting.

But that R&G kit is like 300 bones!!! Very nice kit though.

aww.. *group hug* :) lol

Greg are you doing a DIY on the mirrors? and are those the ebay universal ones and did you modify the stalk any or did you just mount them as is? looks great man! good job

Lol, I'm feeling the love :drinkpals:
I saw the ebay ones and they look a hell of alot like mine, I guess they're the same, but I bought mine from here

www.mandp.co.uk (http://www.mandp.co.uk/productInfo.aspx?catRef=568198)

For a DIY on these - there's a new thread that I'll complete asap. :)

Nice! Those sliders seem to have a better design than the other ones out here. It seems less likely to snap or bend.

Thanks. I've never seen rg parts untill this thread. Their site says the kit is UK bike only...anyone know why? I like their exhaust hanger

Thanks. I've never seen rg parts untill this thread. Their site says the kit is UK bike only...anyone know why? I like their exhaust hanger

The carb models have there ignition coil on both sides, right were that plate is. Also the Cali model has its emisions stuff there too.

Looks like a real nice kit! Might be worth it to have, even if you gotta modify something for it to fit(carb versions).

Completed the DIY. Updated parts are in post 2

very nice! the rear view shot might turn out a little bit better if you cover the plate so you don't have the flash reflecting off of it and washing everything out...

so what's the verdict 250 gurus... will it work on the carb'd version?

very nice! the rear view shot might turn out a little bit better if you cover the plate so you don't have the flash reflecting off of it and washing everything out...

Thanks for the tip. The fairings are off again at the moment. I'm having to apply a lacquer to the lightning. It's just all edge and points, a snagging nightmare lol. Will update with a better rear picture when the fairings are back on :)

I'm really wondering now if these will work on the carb models. Especially after seeing and hearing about how the intuitive and shogun sliders are holding up to crashes...

I'm really wondering now if these will work on the carb models. Especially after seeing and hearing about how the intuitive and shogun sliders are holding up to crashes...

Where did you hear about these things?
I've been looking for information because I would really like to prevent as much damage as possible to my bike and would really like to invest in some sliders/crash protectors!

Shogun: Check out post #18

http://www.ninjette.org/forums/showthread.php?t=11224

Intuitive Sliders:

http://www.kawiforums.com/showthread.php?t=119815&page=9

Thank ya kindly!:)
I'm still leaning towards putting them on though... I'm thinking I'm more likely to drop it when I'm stopped or going slow. I don't plan on going fast until I get good at going slow!

I'm really wondering now if these will work on the carb models. Especially after seeing and hearing about how the intuitive and shogun sliders are holding up to crashes...

I think broom f-ed his shoguns up pretty bad. Don't know how fast he was goin but if I had his jacket I'd be goin pretty fast.

Just took a look at my bike this morning. There looks to be all kinds of smog and ignition crap, brackets, etc in the way. So I think these RG racing sliders are a no go for our carbied ninjettes. Im going with the shoguns since they seem to be best out of whats available to us and Richard of racebikerentals.com just so happens to offer them at the lowest price I could find online...:thumbup:

+1 forum member.

I need to by sliders too. I can't afford another down without them. I'll probably buy from rich aswell. Maybe he can get us a group buy.

A group buy would be wonderful. I would definitely be down for that!

theres two

ihatethisforum:hitself:ihatethisforum:hitself:ihatethisforum:hitself:
ihatethisforum:hitself:ihatethisforum:hitself:ihatethisforum:hitself:
ihatethisforum:hitself:ihatethisforum:hitself:ihatethisforum:hitself:

count me in

ihatethisforum:hitself:ihatethisforum:hitself:ihatethisforum:hitself:
ihatethisforum:hitself:ihatethisforum:hitself:ihatethisforum:hitself:
ihatethisforum:hitself:ihatethisforum:hitself:ihatethisforum:hitself:

Good job! :thumbup:

Just a question: where do you buy this crash protectors? And what is the price please?
Because I would like to buy crash protectors for my ninja and I hesitate between R&G and shogun, but I don't found none of them in EU...

thats a possible four. I'm PMing richard to see what he says. I'll post back ASAP.

thats a possible four. I'm PMing richard to see what he says. I'll post back ASAP.

Wait, I thought this doesn't work on the US bikes.

Good job! :thumbup:

Just a question: where do you buy this crash protectors? And what is the price please?
Because I would like to buy crash protectors for my ninja and I hesitate between R&G and shogun, but I don't found none of them in EU...

Emanuelle,
R&G is a UK company
http://www.rg-racing.com/browseBike/Kawasaki/ZX250_(Ninja_250R)/2008.aspx

Wait, I thought this doesn't work on the US bikes.

We are talkin about the shoguns. racebikerentals doesnt have R&G:)

We are talkin about the shoguns. racebikerentals doesnt have R&G:)

Got my hopes up... because the R&G looks really nice.

Wonder what the resistance is on those overseas ignition coils, maybe somebody with a fi manual look that up? Would be pretty slick to change over to those, instead of relocating ours. Would be allot cleaner & and no spark plug wires :)

Guess coming up with a set of those would be just as easy as them 250r rear stickers, tried every country and nobody would ship.

Nobody would ship you stickers? Im sure you can have them made.

check this thread:

http://www.ninjette.org/forums/showthread.php?t=15089&highlight=logo

I got impatient and ordered a set of Shoguns from Rich, but a group buy would be a great idea for those who can wait..

I recently emailed R&G to ask for specifics on why their sliders wouldn't work on US models and this was the reply I received:

"I believe the ignition coils on overseas models are mounted precisely where our crash protectors are located. Apologies for the inconvenience :-)"

I was thinking the same thing about switching to the FI coil, but there seems to be another problem. The coils on our US models mount to brackets that look to be welded on and might get in the way of the R&G mounting plate. It looks like their plate has to mount flat to the existing plate on our bikes. Now assuming the coils are the only thing you have to move out of the way, you could prob just cut the brackets off for a flat mounting surface, then in that case it could work.
I didn't get a comprehensive look at the mounting area since I was just looking through the hole in the fairings and comparing it to the pics in this DIY...
Really a shame too, since these sliders look really nice and well constructed :mad:

Emanuelle,
R&G is a UK company
http://www.rg-racing.com/browseBike/Kawasaki/ZX250_(Ninja_250R)/2008.aspx
Thanks for the link!:thumbup:

The exhaust protector is also great: http://www.rg-racing.com/browseBike/Kawasaki/ZX250_(Ninja_250R)/2008/EP0005BK.aspx

Gregular, do you think R&G crash protectors are as protective than shoguns?

I'm down for the group buy :)
Posted via Mobile Device

Shogun Group buy thread:

http://www.ninjette.org/forums/showthread.php?p=38530#post38530

Just an update with some pics of some field tests that weren't intended but ended up ok

Left side - pretty much a stationary drop, I'd just pulled into the driveway and as I was stopping the garage door opened up and I was then caught in two minds as to where to get off and next thing I knew, bike was on the floor

http://www.ninjette.org/forums/picture.php?albumid=59&pictureid=1793

http://www.ninjette.org/forums/picture.php?albumid=59&pictureid=1794

Right side - happened when I got over confident and thought I could do a u-turn and use an iphone as a sat nav at the same time

http://www.ninjette.org/forums/picture.php?albumid=59&pictureid=1795

http://www.ninjette.org/forums/picture.php?albumid=59&pictureid=1796

Good news is the protectors did their job :) with only slight scuffs/dinks to the footpegs and nothing else was damaged

Thanks for the link!:thumbup:

The exhaust protector is also great: http://www.rg-racing.com/browseBike/Kawasaki/ZX250_(Ninja_250R)/2008/EP0005BK.aspx

Gregular, do you think R&G crash protectors are as protective than shoguns?

Couldn't say, I have no experience of Shogun parts. Hopefully the pics above might help

Greg - I'm sorry to hear about your drops, but glad to see they held up well! We've missed you posting around here - you must be out riding too much :)

Greg - sorry it went over - looks like the crash protectors kept it safe though - dropped mine trying a u-turn too - about the same amount of damage as yours - ie not much! lol

I got impatient and ordered a set of Shoguns from Rich, but a group buy would be a great idea for those who can wait..

I recently emailed R&G to ask for specifics on why their sliders wouldn't work on US models and this was the reply I received:

"I believe the ignition coils on overseas models are mounted precisely where our crash protectors are located. Apologies for the inconvenience :-)"

I was thinking the same thing about switching to the FI coil, but there seems to be another problem. The coils on our US models mount to brackets that look to be welded on and might get in the way of the R&G mounting plate. It looks like their plate has to mount flat to the existing plate on our bikes. Now assuming the coils are the only thing you have to move out of the way, you could prob just cut the brackets off for a flat mounting surface, then in that case it could work.
I didn't get a comprehensive look at the mounting area since I was just looking through the hole in the fairings and comparing it to the pics in this DIY...
Really a shame too, since these sliders look really nice and well constructed :mad:

Yup - the brackets have another bracket welded on for the ignition coils. I think a shop could modify the brackets easily enough, or perhaps you could get a set off of a wrecked FI version, but you'd still need to find a new home for the coils....

I have gone ahead and ordered the R&G Sliders to install on my US 2009 Special Edition. Seems like no one else has tried to do this to a US version of the 250R so I guess I will be the first. I just picked them up from ebay for $159 from Cali.

I will post the installation and what I will be doing to make these work! = )

Stay tuned, I will start a new thread.

Good luck John! I had really wanted to do this, but the ones I have are working fine for now. If they ever need to be replaced, I'll be using these and moving the ignition coils for sure :)

:D They worth every penny !

Parts are on! - I needed to move the coils above the R&G support! I had to cut the OEM bracket off with a dremel and grind down the welds to make the R&G bracket flushed with the frame. Did a test fit with the fairings and the supports are spot on. Excellent design. I have not finished the install yet as I am still waiting for parts to come back from paint. I will have it completely finished then.

Oh BTW, I was able to source the parts from EBAY from a R&G Supplier. It states on the auction that it will NOT fit US model and only EU models. They were taking best offers and I got it for $159.00 = ) - Most expensive sliders ever but if looks like they do the job very well!