I never finished this thread, and it's been quite some time but I finally finished the bike! It runs great, and isn't far off the mark of what I wanted for it.
While it ultimately was more work than is worth it in the future, I brought it back from the dead, and learned a lot in the process.
Currently selling it in SoCal if anyone's interested (Clean Oregon title). I built it intending to take it to the track, but on a budget. More work than cost went into this ultimately, I kept major modifications to a minimum. The key focus was reliability and handling. It has a 2010 Ninja 250 rear shock so the pre-load is adjustable. A short list of what was done:
- Top end completely rebuilt and broken in.
- Carbs freshly sonic cleaned, rebuilt, and jetted and shimmed for pod filters with OEM exhaust
- New pod filters
- Forks rebuilt, new oil and seals
- Fresh coats of paint on exhaust
- All fluids (coolant, oil, brake fluid) flushed and brand new
- New K&N oil filter
- New brake pads
- Bodywork repainted
- Swingarm refreshed and repainted
- 2010 Ninja 250 adjustable rear shock
- New battery
- New spark plugs
- All LED lighting and digital cluster
- Integrated tail light
- Rear fender eliminated
- New chain
- Purple OEM powder coated wheels with new bearings, seals, and valve stems
- New Pirelli Diablo Scooter Tires (110/70-16 Front, 130/80-16 Rear)
- Second set of wheels with good Dunlops still mounted
- Clip on handlebars and new grips
- Entire bike tore down, cleaned, re-greased
A few photos of the finished product:
