November 6th, 2018, 04:28 PM | #1 |
2-18 wheels
Name: Bradley
Location: Dayton, Ohio.
Join Date: Aug 2018 Motorcycle(s): ‘04 Kawasaki Ninja 250 “Baroness” Posts: 87
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Winter rebuild time. With questions and updates.
Ok so I am finally ready to admit my personal riding season has ended...but on the plus side it’s rebuild/maintenance time.
I’ll post the full to do list as well as progress as it happens but I need info to start one major part. I hate the way my exhaust sounds (wait don’t click away!) it’s too -redacted- loud way way too loud. I’m struggling to find an exhaust rebuild thread that is aimed at making quiet all I can seem to find is aimed to make loud. Should I just pull the mufflers and repack them? Potentially have things welded? I’m useless at exhaust.
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November 6th, 2018, 04:32 PM | #2 |
Guy Who Enjoys Riding
Name: Jim
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Stock pregen mufflers are not loud. Has someone modified it, for example by drilling out the four rivets on each muffler? Or maybe even something worse.
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November 6th, 2018, 04:36 PM | #3 |
2-18 wheels
Name: Bradley
Location: Dayton, Ohio.
Join Date: Aug 2018 Motorcycle(s): ‘04 Kawasaki Ninja 250 “Baroness” Posts: 87
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These holes?
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November 6th, 2018, 06:18 PM | #4 |
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Endcap is missing
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November 6th, 2018, 06:58 PM | #5 |
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more missing than just endcaps, that thing is gutted.
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November 6th, 2018, 07:54 PM | #6 |
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You need cap and small tube to connect to inner tube shown.
Surely someone has set in box somewhere they're not using? |
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November 6th, 2018, 09:11 PM | #7 |
2-18 wheels
Name: Bradley
Location: Dayton, Ohio.
Join Date: Aug 2018 Motorcycle(s): ‘04 Kawasaki Ninja 250 “Baroness” Posts: 87
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Is there a diagram of the complete muffler assembly? Preferable blown apart to show all the pieces?
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November 7th, 2018, 06:07 AM | #8 |
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I've never seen a diagram, as they are a one piece welded unit from the factory, I doubt one exists. Your best bet is to locate a pair of used mufflers.
Here's a few pics I took of one I opened up on the inlet side https://www.ninjette.org/forums/showthread.php?t=322941
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November 7th, 2018, 06:20 AM | #9 |
2-18 wheels
Name: Bradley
Location: Dayton, Ohio.
Join Date: Aug 2018 Motorcycle(s): ‘04 Kawasaki Ninja 250 “Baroness” Posts: 87
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Pretty sure I can cut mine open have the center perfed pipe welded in place and then weld em back together for close to $50 should I add some muffler pack material around the center?
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November 7th, 2018, 06:41 AM | #10 |
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Do what you want, but I've seen people giving pregen systems away for free.
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November 7th, 2018, 07:00 AM | #11 |
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I'm looking at set of EX500 mufflers. They appear to be similar and might fit. I'll try to swap them in over weekend. If they do fit, they're yours for cost of shipping.
Interesting that new-gen with single muffler is actually quieter than pre-gen with two... hmmm... |
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November 7th, 2018, 07:06 AM | #12 |
2-18 wheels
Name: Bradley
Location: Dayton, Ohio.
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I have no effective words for that offer...thank you @DannoXYZ
@Z1R rider where? Just asking because finding deals is a weak point in my skill set.
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November 7th, 2018, 07:32 AM | #13 | |
ninjette.org certified postwhore
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Quote:
On this site sometimes, they're a helpful bunch! My son picked up a set from one of the members on here, for free as they were cleaning the garage. I've seen them on ebay for next to nothing at times, shipping may be prohibitive, I've never looked into it. You could post up in the "Items Wanted" section here and see what shakes out. Also keep an eye on the "Free Stuff" section.
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November 7th, 2018, 09:11 AM | #14 |
2-18 wheels
Name: Bradley
Location: Dayton, Ohio.
Join Date: Aug 2018 Motorcycle(s): ‘04 Kawasaki Ninja 250 “Baroness” Posts: 87
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Found a full set on eBay for around $45 didn’t ask shipping have to wait and see wether my attempted home brew muffler repair works.
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November 8th, 2018, 08:14 AM | #15 |
2-18 wheels
Name: Bradley
Location: Dayton, Ohio.
Join Date: Aug 2018 Motorcycle(s): ‘04 Kawasaki Ninja 250 “Baroness” Posts: 87
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To do list: strip all plastic off (done)
Remove carb (done) Send carb off for fixen Re align tire and make direction correct. Remove and clean air box Replace fluids and filters. Repair cracked plastics Re lube things. Loctite things. Rebuild/replace mufflers Remove mufflers (done) Gaze wistfully at the most-of-a-cycle and dream of riding season (current) Put back together Adjust valves (thanks for the reminder jkv45) RIDE!
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November 8th, 2018, 08:18 AM | #16 |
Rev Limiter
Name: Jay
Location: WI
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I'd also check the valve clearances while you have everything apart.
https://faq.ninja250.org/wiki/Hints_...lve_Adjustment https://faq.ninja250.org/wiki/J_Valve_adjustment |
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November 8th, 2018, 08:21 AM | #17 |
2-18 wheels
Name: Bradley
Location: Dayton, Ohio.
Join Date: Aug 2018 Motorcycle(s): ‘04 Kawasaki Ninja 250 “Baroness” Posts: 87
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Pic 1 Getting naked.
Pic 2 and 3 heat damage? Pic 4 crack needing fixed. Abs correct?
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November 8th, 2018, 08:23 AM | #18 |
2-18 wheels
Name: Bradley
Location: Dayton, Ohio.
Join Date: Aug 2018 Motorcycle(s): ‘04 Kawasaki Ninja 250 “Baroness” Posts: 87
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Re align? I’m not seeing any frame twisting or bends
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November 8th, 2018, 08:24 AM | #19 |
2-18 wheels
Name: Bradley
Location: Dayton, Ohio.
Join Date: Aug 2018 Motorcycle(s): ‘04 Kawasaki Ninja 250 “Baroness” Posts: 87
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Ewww gross need to pull and clean airbox...speaking of who decided to put it there!? So much trouble to pull carb
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November 8th, 2018, 08:26 AM | #20 |
2-18 wheels
Name: Bradley
Location: Dayton, Ohio.
Join Date: Aug 2018 Motorcycle(s): ‘04 Kawasaki Ninja 250 “Baroness” Posts: 87
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The potential source of my woes lookit the disintegrating foam in the tiny holes
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November 8th, 2018, 08:29 AM | #21 |
2-18 wheels
Name: Bradley
Location: Dayton, Ohio.
Join Date: Aug 2018 Motorcycle(s): ‘04 Kawasaki Ninja 250 “Baroness” Posts: 87
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Little tube inside the muffler appears perforated which side (back or front) of the muffler does it attach to normally? Thinking of cutting at the weld my finger is on to have it re welded in place and then the cut weld re welded. Just a thought.
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November 8th, 2018, 12:25 PM | #22 |
ninjette.org certified postwhore
Name: Roger
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The pics in the link (#8 above) are what I found cutting the front weld, I never did cut the rear one. The way it looked to me is the tubes and baffles in the muffler are all spot welded in place and would be pretty hard to take out without destroying the muffler. Of course the ones you have look to be gutted, with all the baffling and routing tubes removed by whatever means. It is tough to beat the performance of the factory engineered stock mufflers.
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November 8th, 2018, 02:51 PM | #23 | |
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Quote:
But from looking at it, you probably won't need to do that even. Just make flat-disc that fits ID of muffler outlet. Cut hole in centre for tube of correct size and length to go down and join with centre tube. Weld tube to end-cap. Then insert end-cap to muffler outlet. |
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November 8th, 2018, 03:02 PM | #24 |
2-18 wheels
Name: Bradley
Location: Dayton, Ohio.
Join Date: Aug 2018 Motorcycle(s): ‘04 Kawasaki Ninja 250 “Baroness” Posts: 87
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The baffle tubes in mine are loose indicating to me the spot welds on the back side are broken so probably next week I’ll cut the rear weld fill in the four holes where there used to be rivets weld baffle tube to the rear plate re align and re weld back together. Could be interesting it may just fix it.
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November 22nd, 2018, 10:12 AM | #25 |
2-18 wheels
Name: Bradley
Location: Dayton, Ohio.
Join Date: Aug 2018 Motorcycle(s): ‘04 Kawasaki Ninja 250 “Baroness” Posts: 87
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Ok so let’s see if I have this right. Exhaust gassed mover from motor to muffler via small tubes (circled) then nearly reverse to travel up a “collar” into the perforated tube in the center then exit via smaller hole in center (green arrow) and that tube is supposed to be mated to the end cap with no gaps so gassed are forced to go the long way correct? If so I can probably fix this with a bit of exhaust piping and some creative welding if I am wrong...suggestions?
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November 22nd, 2018, 10:28 AM | #26 |
2-18 wheels
Name: Bradley
Location: Dayton, Ohio.
Join Date: Aug 2018 Motorcycle(s): ‘04 Kawasaki Ninja 250 “Baroness” Posts: 87
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Muffler rebuild may turn into a hobby item found multiple mufflers in better shape than mine on eBay running $5-$70 each variety of shipping cost looks like a decent pair will average out at $150 shipped. So very tempting...
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December 4th, 2018, 06:29 AM | #27 |
2-18 wheels
Name: Bradley
Location: Dayton, Ohio.
Join Date: Aug 2018 Motorcycle(s): ‘04 Kawasaki Ninja 250 “Baroness” Posts: 87
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Ok here’s a stupid or genius solution.
Parts laid out like so, welded in place tapped down and welded back together. $3 fix?
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December 4th, 2018, 02:23 PM | #28 |
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Hey, that looks pretty awesome. Did that quiet down the bike?
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December 4th, 2018, 02:55 PM | #29 |
2-18 wheels
Name: Bradley
Location: Dayton, Ohio.
Join Date: Aug 2018 Motorcycle(s): ‘04 Kawasaki Ninja 250 “Baroness” Posts: 87
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No idea lol carb is sitting in a box. On the plus side though it’s seems like it’ll work.
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April 23rd, 2019, 11:46 AM | #30 |
2-18 wheels
Name: Bradley
Location: Dayton, Ohio.
Join Date: Aug 2018 Motorcycle(s): ‘04 Kawasaki Ninja 250 “Baroness” Posts: 87
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Big update. Finally got bike back together a few days ago carb running smoothly sounded great with the muffler mod. Changed air filter cleaned air box. Oil change new spark plugs. Replaced front turn signals. Etc etc. anyways got it running smooth and happy.
Sunday decided to take a test ride see how it’s doing and about 30 miles in a loud pop was heard and the bike promptly died. Took it apart again yesterday and found the timing chain snapped and in the ensuing chaos 4 of 8 valve lifters are blown off some in pieces some whole but the screws holding them snapped. Found 3 of them meaning 1 has worked it’s way in parts or whole into the lower motor. I see 3 options none are particularly great. 1 replace motor. 2 replace bike. 3 overhaul engine. Sadness. My riding season may have already ended.
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April 23rd, 2019, 12:46 PM | #31 |
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Name: Hector
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Damn, tough break!
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April 23rd, 2019, 01:23 PM | #32 |
2-18 wheels
Name: Bradley
Location: Dayton, Ohio.
Join Date: Aug 2018 Motorcycle(s): ‘04 Kawasaki Ninja 250 “Baroness” Posts: 87
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See. It’s not happy
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April 23rd, 2019, 01:37 PM | #33 |
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Take head off to see if pistons have been perforated or cylinders scored. Most of the time, tiny scratch on piston and broken-off valve-heads and bent stems. Those can be replaced.
Best case scenario, used head and timing-chain for $200-300 Worse case, used engine for $300-600 |
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April 23rd, 2019, 01:43 PM | #34 |
2-18 wheels
Name: Bradley
Location: Dayton, Ohio.
Join Date: Aug 2018 Motorcycle(s): ‘04 Kawasaki Ninja 250 “Baroness” Posts: 87
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There are 3 of 4 valve lifters? (I think that’s what they are called) anyways what kinda lower damage am I looking to run into since 1 of those is awol and likely visiting my transmission at this point
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April 23rd, 2019, 03:45 PM | #35 |
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Rocker-arms. They're weak-point of these engines when improper valve-adjustment and/or locknut torque is used.
Pieces would fall into oil-pan and stay there, so not likely to harm anything. Should still pull off oil-pan to inspect while replacing head. Might not be worth trouble of measuring remaining rocker-arms, cams, valve-stems and valve-guides to determine how many of them to replace. Last futzed with by DannoXYZ; April 23rd, 2019 at 09:10 PM. |
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April 24th, 2019, 03:37 AM | #36 |
2-18 wheels
Name: Bradley
Location: Dayton, Ohio.
Join Date: Aug 2018 Motorcycle(s): ‘04 Kawasaki Ninja 250 “Baroness” Posts: 87
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So you’re saying the head probably needs replaced? Now I guess it’s time to start sourcing parts. Thinking of starting in a junkyard looking at wrecked
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April 24th, 2019, 08:07 AM | #37 |
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At very least new head due to all work involved with repairing existing one. Still lots of effort. Complete engine would be easiest. Keep eye on local ads.
https://sfbay.craigslist.org/eby/mpo...871460866.html |
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April 24th, 2019, 10:17 AM | #38 |
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Ouch. I hope your fix isn't too bad and you get back to riding.
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April 24th, 2019, 11:13 AM | #39 |
2-18 wheels
Name: Bradley
Location: Dayton, Ohio.
Join Date: Aug 2018 Motorcycle(s): ‘04 Kawasaki Ninja 250 “Baroness” Posts: 87
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Sent an email off on a “parts bike” I found on local CL. Wait and see now
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April 24th, 2019, 05:05 PM | #40 |
2-18 wheels
Name: Bradley
Location: Dayton, Ohio.
Join Date: Aug 2018 Motorcycle(s): ‘04 Kawasaki Ninja 250 “Baroness” Posts: 87
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Anyone know a way to run a VIN on a missing title bike to confirm non theft?
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