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Old January 14th, 2019, 06:08 AM   #13
Skrrrt
ninjette.org member
 
Name: Ninja
Location: Washington
Join Date: Jan 2019

Motorcycle(s): 2008 Ninja 250

Posts: 24
Quote:
Originally Posted by DannoXYZ View Post
You actually don't need support rails. Original engine is stressed-member, so just make some custom mounts to hang front of engine. Otherwise you'll need two custom mounts per side to attach EX500 lower rails. And you won't even come close to fitting fairings back on with those in place.

You'll also need 500 instrument cluster if you want tach, different ignition-timing. As well as 500 ignition-box. Thermostat assembly and hoses. Better to move that to side like on 250. Will need to make some brackets top & bottom to attach 500 radiator.

Search on here for 500 swaps, there's some with really good photos. If you have mini-lathe, plasma-cutter and TIG torche, that'll make things A LOT easier.

Sprockets should be 16/42t (some chains with tall plates won't fit under sprocket cover). I'm using new-gen rear-suspension on my pre-gen with ex500 rear-wheel & sprocket for 17" conversion (mine came with 41t). EX500 engine weighs 26-lbs more than 250, so plan on re-calibrating suspension accordingly, it's definitely noticeable. Also upgrade your brake-pads to Galfer to deal with extra weight and speed. Factory OEM pads have very non-linear grip & feel. Initial bite is too sensitive and when you squeeze harder, "oh ****! Where's my brakes!?!@#$!?.

I opted out for the cluster/tach I use my phone mount as a speedo.
I will return the engine rails just thought I could make it work using the stock engine mounts, but I can custom weld something on no problem, as for fairings... there will be done as you can see on the bike ! it is Naked (:
got a welder but not a plasma cutter ): definitely would make my life easier but for now a angle grinder gotta do lol.
just made an order for the (CDI)"ignition box"
silicone hoses and thermostat came with the new radiator!
will be looking into sprockets and make the order once I'm off work, you are totally right on the brakes, first thing I did when ride is practice my braking and body that POS needs some work I catch myself dragging the rear wheel until a stop LOL"can't lie its fun"
as for the rear shock I'm letting race tech install a gs-3 shock on there and adjust it for my weight, and height.

so for my list is checking out and my swap is ready !(: thank you guys !!
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