@
DannoXYZ, Thanks for the reply. 40 pounds was about the numbers I came up with too, haven't bothered weighing things so far but I might compare to a stock EX250 and EX500 when done (I have access to both). from my estimates and calculations, if I can make about 60 BHP (I will be doing a port and polish and building of the engine, as well as intake, exhaust, and AFR tuning, so I think 60 isn't unreasonable at all for a healthy engine), that should put me around the 330 bhp/tonne range which is about the same as the ninja 650. Motor mounts, I will deal with. But I have access to a TIG welder at least if I do need to modify. And bodywork, if it ends up slightly flared out like i've seen I will 3D print and colour match an adapter plate. However I will be fabricating an exhaust to try to avoid this.
Engine mounts: This is the first solid advice i've seen/heard on that front so I really appreciate it and will take that into consideration.
Exhaust: I plan on attempting to fabricate a dual exhaust that goes out the right side of the bike, with two cans. I really like that look. I think there will be space to do it since it is a hanging engine. I would like to build an X pipe instead of the 500's "H pipe" style, Where an O2 Bung will be welded into the middle of the X pipe for my wideband. My only concern is placement of the X pipe, I think unfortunately the oil filter may interfere with the design. But I don't mind removing my exhaust to change oil filter, I honestly don't care. Worst case scenario I will build a 2-1 system.
Tach: I'm working on something custom for the gauge cluster to hold my wideband and display everything I want to, so the stock tachometer will not be used anyway
Rad: I was actually hoping I could get away with the 250 rad. Opinions? I will be running an ECT sensor to monitor and if the cooling isn't adequate could add the 500 rad later. But looking at them it really doesn't seem much smaller.