July 14th, 2016, 08:04 PM | #1 |
ninjette.org guru
Name: Miguel
Location: MA
Join Date: Jan 2015 Motorcycle(s): 2000 EX-250; several other years of the same Posts: 470
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94 refurbishment
I am continually searching Craig's List for deals. I came across this just a few days ago, and could not pass it up. As I have (gasp) 3 pre-gens now, I purchased this one with the intent to go thru it and sell it. I have so many spare parts, that I hope not to need to purchase much. I was told that "it ran when parked - 5 years ago". I have not done anything to it yet, but can tell that the front brake is frozen, the entire exhaust is heavily rusted, and the inside of the fuel tank is rusted. I have not even attempted to turn the motor over. Wish me luck!
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July 14th, 2016, 08:10 PM | #2 |
ninjette.org guru
Name: Miguel
Location: MA
Join Date: Jan 2015 Motorcycle(s): 2000 EX-250; several other years of the same Posts: 470
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Parts from this conglomeration, and this matched set of fairings most likely will be incorporated into the project.
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July 14th, 2016, 09:50 PM | #3 |
in your machine
Name: Scott
Location: Summer Shade, Ky.
Join Date: Oct 2014 Motorcycle(s): 98 Ninja 250/F12 aka ZX-2R "SERENITY", 91 Ninja 500/A5 aka ZX-5R "Phoenix", 84 Honda GL1200A "SIREN" Posts: A lot.
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Luck
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July 15th, 2016, 07:47 PM | #4 |
ninjette.org guru
Name: Miguel
Location: MA
Join Date: Jan 2015 Motorcycle(s): 2000 EX-250; several other years of the same Posts: 470
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Drained the oil today, and turned the engine over by hand. It turns freely. I am in the process of swapping out the carbs, and my good fuel tank and battery, to see if it fires up and drives.
I know that I will need to replace all of this. Brake fluid too, but I need to buy some, fresh.
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July 16th, 2016, 09:28 PM | #5 |
ninjette.org guru
Name: Miguel
Location: MA
Join Date: Jan 2015 Motorcycle(s): 2000 EX-250; several other years of the same Posts: 470
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Oil / filter / screen cleaned and changed. Carbs, fuel tank, and battery swapped. Ignition - on. "dashboard" lights on. Nothing else . No headlight, turn signals, starter - nada. I checked the fuses - all good. I jumped the kickstand safety switch. I used a volt meter on the battery 12.6 ish volts. I visually inspected the wiring harness, wherever visible for being chewed through ( there was a nest in the tail ).
It is in neutral, and I will try to jump the clutch safety switch next time. But, why no horn, headlights, or turn signals?
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July 18th, 2016, 09:00 AM | #6 |
ninjette.org guru
Name: Miguel
Location: MA
Join Date: Jan 2015 Motorcycle(s): 2000 EX-250; several other years of the same Posts: 470
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I searched the "interwebs" and found ideas to isolate:
main ground to engine - check / clean / tighten ignition switch ( I have a spare to swap out ) bad starter ( as power first goes to it, then to the est of the bike? )
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July 19th, 2016, 03:28 AM | #7 |
ninjette.org guru
Name: Miguel
Location: MA
Join Date: Jan 2015 Motorcycle(s): 2000 EX-250; several other years of the same Posts: 470
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It's alive - electrically speaking.
I replaced so many parts last night, but finally determined that the starter switch, on the right hand control was bad. I swapped it with a spare and the engine turns over. Horn, turn signals, brake light, headlights , dash - all working. Now, to hook up the fuel tank and start it...
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July 19th, 2016, 03:29 AM | #8 |
ninjette.org guru
Name: Miguel
Location: MA
Join Date: Jan 2015 Motorcycle(s): 2000 EX-250; several other years of the same Posts: 470
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The list of things to address...
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July 19th, 2016, 09:53 AM | #9 |
ninjette.org member
Name: Jay
Location: SC
Join Date: Jun 2016 Motorcycle(s): 1993 ninja 250ex Posts: 21
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July 22nd, 2016, 04:29 AM | #10 |
ninjette.org guru
Name: Miguel
Location: MA
Join Date: Jan 2015 Motorcycle(s): 2000 EX-250; several other years of the same Posts: 470
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I had it running for 5 straight minutes last night! I didn't have time to go for a test ride.
So far I have replace both handlebar controls, and the entire front brake set up ( caliper / cable / mount / lever ), and the oil & filter.
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July 23rd, 2016, 05:50 AM | #11 |
ninjette.org guru
Name: Miguel
Location: MA
Join Date: Jan 2015 Motorcycle(s): 2000 EX-250; several other years of the same Posts: 470
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I went for a ride around the block yesterday - all works! Now, to clean, polish, and replace until it looks presentable.
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July 23rd, 2016, 10:22 AM | #12 |
ninjette.org member
Name: Justin
Location: Maine
Join Date: Jul 2016 Motorcycle(s): '05 Ninja 250, '16 Ninja 300 Posts: 113
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Nice work! Cant wait to see it when it's done. I've always wanted to find an old bike and bring it back to life but I just don't have the patience for it.
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July 23rd, 2016, 10:25 AM | #13 | |
EX500 full of EX250 parts
Name: Bill
Location: Grand Rapids-ish, MI
Join Date: Jul 2012 Motorcycle(s): '18 Ninja 400 • '09 Ninja 500R (selling) • '98 VFR800 (project) • '85 Vulcan VN700 (sold) Posts: A lot.
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Quote:
Also, the sidestand switch has nothing to do with starting the bike, only running once it's been started. The starter circuit relay is wired directly to the clutch switch, which passes through to the neutral switch. If you unplug the clutch switch, the starter button will be completely dead, regardless of neutral or sidestand status. The igniter can ground via any of the three safety switches, so the sidstand switch only comes into play once the bike is in gear with the clutch released.
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July 23rd, 2016, 12:35 PM | #14 | |
ninjette.org guru
Name: Miguel
Location: MA
Join Date: Jan 2015 Motorcycle(s): 2000 EX-250; several other years of the same Posts: 470
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Quote:
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July 23rd, 2016, 12:37 PM | #15 |
ninjette.org guru
Name: Miguel
Location: MA
Join Date: Jan 2015 Motorcycle(s): 2000 EX-250; several other years of the same Posts: 470
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I drained the fuel tank today - yuck!
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July 27th, 2016, 07:07 PM | #16 |
ninjette.org guru
Name: Miguel
Location: MA
Join Date: Jan 2015 Motorcycle(s): 2000 EX-250; several other years of the same Posts: 470
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Cleaned and rebuilt the petcock. Used pipe cleaners, and dental brushes to clean all of the orifices. I found one rebuild kit that has all of the components - unlike the ninja 250 site that states 2 kits are needed.
For $30, I thought that I would try it.
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July 27th, 2016, 08:58 PM | #17 |
in your machine
Name: Scott
Location: Summer Shade, Ky.
Join Date: Oct 2014 Motorcycle(s): 98 Ninja 250/F12 aka ZX-2R "SERENITY", 91 Ninja 500/A5 aka ZX-5R "Phoenix", 84 Honda GL1200A "SIREN" Posts: A lot.
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I'm curious which kit you ordered? Was it for the Ninjette? Another model?
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July 28th, 2016, 06:55 AM | #18 |
ninjette.org guru
Name: Miguel
Location: MA
Join Date: Jan 2015 Motorcycle(s): 2000 EX-250; several other years of the same Posts: 470
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As pictured, K&L 18-2702. I found it on eBay, listed specifically for the pre-gens. Everything seemed to be the correct parts. I won't know for sure until the bike is back together, and I test ride it.
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July 28th, 2016, 07:53 AM | #19 |
in your machine
Name: Scott
Location: Summer Shade, Ky.
Join Date: Oct 2014 Motorcycle(s): 98 Ninja 250/F12 aka ZX-2R "SERENITY", 91 Ninja 500/A5 aka ZX-5R "Phoenix", 84 Honda GL1200A "SIREN" Posts: A lot.
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Very cool to know they finally make one kit.
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July 28th, 2016, 07:58 AM | #20 |
ninjette.org guru
Name: Miguel
Location: MA
Join Date: Jan 2015 Motorcycle(s): 2000 EX-250; several other years of the same Posts: 470
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I agree. How do we let the Ninja 250 FAQ folks know, to update their page?
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July 28th, 2016, 08:03 AM | #21 |
in your machine
Name: Scott
Location: Summer Shade, Ky.
Join Date: Oct 2014 Motorcycle(s): 98 Ninja 250/F12 aka ZX-2R "SERENITY", 91 Ninja 500/A5 aka ZX-5R "Phoenix", 84 Honda GL1200A "SIREN" Posts: A lot.
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I'll make the changes, I'm WIKI ADMIN for them, once you verify the kit is a complete kit, and no need for anything else.
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July 28th, 2016, 08:12 AM | #22 |
in your machine
Name: Scott
Location: Summer Shade, Ky.
Join Date: Oct 2014 Motorcycle(s): 98 Ninja 250/F12 aka ZX-2R "SERENITY", 91 Ninja 500/A5 aka ZX-5R "Phoenix", 84 Honda GL1200A "SIREN" Posts: A lot.
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MOTM - Jun '17, May '16, Mar '15
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Looks like K&L does agree with your findings
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July 28th, 2016, 08:26 AM | #23 |
in your machine
Name: Scott
Location: Summer Shade, Ky.
Join Date: Oct 2014 Motorcycle(s): 98 Ninja 250/F12 aka ZX-2R "SERENITY", 91 Ninja 500/A5 aka ZX-5R "Phoenix", 84 Honda GL1200A "SIREN" Posts: A lot.
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August 1st, 2016, 07:45 AM | #24 |
ninjette.org guru
Name: Miguel
Location: MA
Join Date: Jan 2015 Motorcycle(s): 2000 EX-250; several other years of the same Posts: 470
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I poured 2 gallons of cider vinegar into the fuel tank yesterday. I'll let it steep for a couple of days to see if it touches the rust. I have the tanked turned on its side, as I have not yet plugged the petcock opening. I know that to fill the tank totally, is close to 5 US gallons.
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August 3rd, 2016, 05:48 AM | #25 |
ninjette.org guru
Name: Miguel
Location: MA
Join Date: Jan 2015 Motorcycle(s): 2000 EX-250; several other years of the same Posts: 470
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The cider vinegar is working. I couldn't hold the tank, position a light, and take a picture - but it is working. Now, to plug the petcock opening, and fill the tank.
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August 3rd, 2016, 10:55 PM | #26 |
in your machine
Name: Scott
Location: Summer Shade, Ky.
Join Date: Oct 2014 Motorcycle(s): 98 Ninja 250/F12 aka ZX-2R "SERENITY", 91 Ninja 500/A5 aka ZX-5R "Phoenix", 84 Honda GL1200A "SIREN" Posts: A lot.
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I personally use, and have muriatic acid. Available at Lowe's, or most hardware stores.
It makes quick work of rust inside any tank. Below are pictures of my EX500 tank, before and after. Another option is to take the tank to a radiator repair shop. They can clean it, check it for leaks, holes, etc... And repair them, some shops will also coat the tank. I've had them done in the past for a total of about $75.00, not a bad deal for the services rendered IMHO.
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August 5th, 2016, 05:41 AM | #27 |
Certifiable nontundrum
Name: Harper
Location: NC Milkshake stand
Join Date: Mar 2013 Motorcycle(s): 2013 SE NINJA 300 Posts: Too much.
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When I was your age we put rocks and sand in there with some kind of juice and shook the tank like our life depended on it.
Sweet fix up
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August 6th, 2016, 06:30 AM | #28 | |
ninjette.org guru
Name: Miguel
Location: MA
Join Date: Jan 2015 Motorcycle(s): 2000 EX-250; several other years of the same Posts: 470
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Quote:
I might try adding metal nuts ( no bolts ) and the shake method, if the vinegar doesn't do a complete job. I can fish the nuts out with a magnet afterwards.
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August 6th, 2016, 06:43 AM | #29 | |
Certifiable nontundrum
Name: Harper
Location: NC Milkshake stand
Join Date: Mar 2013 Motorcycle(s): 2013 SE NINJA 300 Posts: Too much.
MOTM - Sep '13, Sep '16
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Quote:
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August 6th, 2016, 11:18 PM | #30 |
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Name: Julius Michael
Location: Philippines
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August 7th, 2016, 11:41 PM | #31 |
ninjette.org guru
Name: Miguel
Location: MA
Join Date: Jan 2015 Motorcycle(s): 2000 EX-250; several other years of the same Posts: 470
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I drained the tank, and the vinegar worked wonders! I didn't even need to use any objects to knock off any rust. Unfortunately, after I rinsed the tank a few times with water, and looked for a container and fuel for a final rinse, it flash rusted. I read that it might do so, but in 10 minutes?
I'll have another overnight soak, and have my ducks lined up and see if I can prevent that from happening again. Here are a few pics of what came out after a week long soak.
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August 7th, 2016, 11:43 PM | #32 |
ninjette.org guru
Name: Miguel
Location: MA
Join Date: Jan 2015 Motorcycle(s): 2000 EX-250; several other years of the same Posts: 470
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I also replaced the fluid in the front forks. I left the seals alone, as the forks had a good feel, and the seals looked OK.
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August 8th, 2016, 06:40 AM | #33 |
ninjette.org certified postwhore
Name: Gordon
Location: new york
Join Date: Sep 2009 Motorcycle(s): '95 DUCATI 900SS/SP '07 DUCATI SS800 '19 HONDA CBR650R Posts: A lot.
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A long term solution...consider coating using POR-15.
Effective stuff, affordable, 3 step chemical process. A lot of effort, but worth it in the end. Tank issues become a distant memory. Used in both my Ducati and VFR (long term keepers) I'm not familiar with Red-kote...I know some folks swear by that stuff too. I think member Ghostt can offer some input on it.
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August 8th, 2016, 06:35 PM | #34 |
ninjette.org guru
Name: Miguel
Location: MA
Join Date: Jan 2015 Motorcycle(s): 2000 EX-250; several other years of the same Posts: 470
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The swing arm - sandblasted, primed, painted, and greased...
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August 9th, 2016, 06:56 AM | #35 | |
ninjette.org guru
Name: Miguel
Location: MA
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Quote:
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August 9th, 2016, 12:30 PM | #36 |
Certifiable nontundrum
Name: Harper
Location: NC Milkshake stand
Join Date: Mar 2013 Motorcycle(s): 2013 SE NINJA 300 Posts: Too much.
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That's cool!
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August 11th, 2016, 09:59 AM | #37 |
ninjette.org member
Name: Justin
Location: Maine
Join Date: Jul 2016 Motorcycle(s): '05 Ninja 250, '16 Ninja 300 Posts: 113
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When I cleaned the rust out of my gs500 tank I immediately rinsed it with 2 stroke gas after I dumped out the baking soda water mix (used to neutralize the acid). It worked well and prevented flash rust.
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August 11th, 2016, 06:30 PM | #38 |
ninjette.org guru
Name: Miguel
Location: MA
Join Date: Jan 2015 Motorcycle(s): 2000 EX-250; several other years of the same Posts: 470
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Agreed. I need to IMMEDIATELY rinse it.
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August 11th, 2016, 06:46 PM | #39 |
Guy Who Enjoys Riding
Name: Jim
Location: North Carolina
Join Date: Jul 2016 Motorcycle(s): Ninja 250 Posts: A lot.
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Not to discredit POR-15, since a lot of guys have had success with it over the years, but Caswell's Phenol Novolac epoxy liner is much more resistant to the junk in modern gasoline. It's used in commercial fuel and chemical storage tanks. Being a thick 2-part epoxy, it sticks well, leaves a thick layer, and hardens quickly without having to evaporate solvents.
The flash rust isn't a big deal. If it were mine, similar to that JJMaine said, I'd pour in some 50-50 oil gasoline mix, shake it around, and dump it out. To prevent it, you can rinse the tank with alcohol to get most of the water out, and then coat it with oil. When I wash a V-8 engine block with soap and hot water before assembling the freshly machined block, in the few minutes it takes to dry, the cylinders get tan colored. But it's so thin and fine it doesn't hurt anything, and wipes off with an oily rag. |
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August 17th, 2016, 06:45 AM | #40 |
ninjette.org guru
Name: Miguel
Location: MA
Join Date: Jan 2015 Motorcycle(s): 2000 EX-250; several other years of the same Posts: 470
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I replaced the rear brake pads last night. The seals, and action looked good. I just cleaned up the caliper, lubed the sliders, and installed new pads.
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