2010 (evolving into a mod thread)

[ninja250]

OK we have a little list going for upgrade 1.5. Finally on to page two so we don't have to load all those pics anymore.

I have EBC front pads coming,
front and rear transparent red braided brake lines
red aluminum ebay pegs
weather resistant cigarette lighter socket and lighter with fuse and mount (for keeping the iphone multimedia center juiced)
idle mixture screw mod
replacement fairing nuts
helmet visor ratchet mechanism repair parts coming
and I have a new mysterious carb hose to ponder.

Also a few small bolts to check over and tighten as I'm at 1600mi already.


Reason for the brake upgrade is I saw a bit of residual fluid around my banjos and thought I'd do a little upgrade while I'm down there to inspect. The red lines should look nice too. Next time I'll go with the Pazzo's to round out the brake system Think the shorties will suit my style.

[laraider]

Originally Posted by ninja250

OK we have a little list going for upgrade 1.5. Finally on to page two so we don't have to load all those pics anymore.

I have EBC front pads coming,
front and rear transparent red braided brake lines
red aluminum ebay pegs
weather resistant cigarette lighter socket and lighter with fuse and mount (for keeping the iphone multimedia center juiced)
idle mixture screw mod
replacement fairing nuts
helmet visor ratchet mechanism repair parts coming
and I have a new mysterious carb hose to ponder.

Also a few small bolts to check over and tighten as I'm at 1600mi already.


Reason for the brake upgrade is I saw a bit of residual fluid around my banjos and thought I'd do a little upgrade while I'm down there to inspect. The red lines should look nice too. Next time I'll go with the Pazzo's to round out the brake system Think the shorties will suit my style.

i don't understand 90% of this, but im jealous, haha.

[ninja250]

Small things here and there when I can basically.
Pics to follow when it all shows up.

Might get to the carbs tomorrow after fixing the sprinklers.

[sixer]

front and rear transparent red braided brake lines-

whered ya get em? and do they have silver-

[ninja250]

lines
http://fatbikez.com/kawasaki-ninja-2...line-kit-.html

pads
http://fatbikez.com/-ebc-front-brake...nja-250r-.html

accessory socket/mount/lighter (will be hooking to switchable power and mounting out of view and out of range of elements)
http://cgi.ebay.com/ebaymotors/Motor...Q5fAccessories

ebay pegs
http://cgi.ebay.com/ebaymotors/88-07...item27a7342929
(source) http://www.ninjette.org/forums/showt...highlight=pegs

well nuts
http://www.desmoparts.com/ducati/wellnut/wellnut.htm
(source) http://www.ninjette.org/forums/showt...highlight=nuts

Idle mixture screw tune
http://www.ninjette.org/forums/showthread.php?t=10246

[sixer]

hey dat wuz quick!!

Thanks Nin

[ninja250]

lol,
You could say a little bit of progress took place this morning.

First up, it was time to solve the battery tender plug wire problem once and for all. I wired the tender to the house and ran it down the same pole that I lock the bike to so when it's stored it can charge. When not in use, the battery tender is turned off via the outlet splitter so it doesn't waste electricity.

Tools required..


From the garage opener socket to mounting the multi tap outlet..


From the outlet to the bike


To the tender wire that I installed in the tail previously


Here is how I turn the tender off when not in use to save electricity.
Transformer drain juice even when not in use. you can tell this because they are still warm/hot!


Now for that carb hose I was talking about earlier. Here it is.
It is just the "carb vent hose". It runs between the two carbs from a T. Not positive exactly why mine is leaking just yet. More on that later.


Then I decided since I Was going to yank the carbs since I don't have a milwuakee ofset driver to open the mixture screws, might as well remove the air box while I'm at it! Out came the battery..


Had to use a "ball driver" to get to the air box hose clamps


Once I dropped the undertail the airbox came out with it..


Buh-Bye!


big empty hole now


side shot


All before lunch!

[ninja250]

For reference..
Here was directions how to remove the air filter box..
http://www.ninjette.org/forums/showthread.php?t=11899

I already plugged CA emissions and clean air off

Here's the Air filter on ebay.. if this expires search for K&N r-0990
http://cgi.ebay.com/ebaymotors/K-N-R...Q5fAccessories

[ninja250]

My naked rear end


Removing the handle bar ends to do the throttle twist reduction mod


Finally got the carb out!


There's where it came from








Here's the side where I will be performing the idle mixture cap removal.

[Momaru]

Originally Posted by ninja250

Once I dropped the undertail the airbox came out with it..

Seriously? I had to take the bloody airbox apart and bend the $%^ out of the metal mesh inside to get it all out. Consider yourself lucky

Also, don't forget to get a breather for your crankcase. Be unfortunate to suck sand/etc into that surprisingly clean, pretty bike o' yours.

Loving the thread/pics/progress updates. Thanks!

[ninja250]

I have a little SS breather filter but not sure if it's the right size. I'm hoping I'll be able to squeeze it on there.

Gotta take a break for today. Been at it since like 7am or something. Might fiddle with the carbs a bit more though. Cleanest thing on the bike. lol

Just gotta hope the air filter I ordered gets here by next Friday or so, so I can have the bike back together for the Saturday Socal GMR ride. If not I'll be making a fabric softener filter. haha

Will probably take a stab at a home made fender eliminator and that throttle twist reduction mod between now and then as well. Think I have some 1.5" PVC laying around here somewhere.

[ninja250]

Bike 12v accessory socket/lighter (to charge phone) and my helmet parts showed up.

Installed the breather filter by connecting it with a vacuum connector to the old breather hose and a few zip ties to itself and the coolant overflow hose to hold it in place.

Also opened up the carb idle mixture screws and re-installed the carbs back into the bike.

Used a 3/8" vacuum coupler from pep boys. The breather filter came from pep boys too.






Poppin' them screws out




Freed up mixture screws


carbs back in the bike


The next step of upgrade 1.5..

[ninja250]

Fixed my helmet today.

Also drilled some holes in the carb connector to brace them. Didn't like the idea of running the zip tie against the vacuum hoses and possibly chaffing them. I imagine I'll fab up a bracket for this later.. that open grommet left from the air box would make a perfect bracket mount.

Didn't get to mounting the accessory socket. Couldn't decide where I wanted it yet.

[ninja250]

Anyone know by chance if I can fit the K&N filter while the tank is installed on the bike? (Through the side panel?) I'd like to get as much as the bike zipped back up as possible.. need to test some wire routing around the plastics of my accessory socket before I finalize them and the air filter has yet to show up.

[rage42]

awesome pics, i like the vantage points. Where do you plan to put the cig lighter?

[ninja250]

I've been stuck pondering that myself the last few days. It is a lot bigger than I anticipated. I won't be happy unless it's hidden or out of the way and waterproof.

Once seated I should be able to tap into switched power no problem though.

I might wait until all the plastic are back on to be sure where I place it really works with the bike all back together. Still waiting on that air filter before I slap it together.

I received an email that my brake lines shipped Friday and the pads were shipping out today.
I think a few other things shipped as well. Hopefully upgrade 1.5 will be done shortly so I can RIDE! haha

[kkim]

kc- hint w/ tie wraps... cut the tails off flush/square with the receiving end. your hands will thank you the next time you go in there fishing around close to the tie wrap ends. they can easily cut skin.

ask me how I know???

[currentsea]

I've been able to remove my K&N air filter from the side without removing the tank, but putting it on is another story. I'd save myself the grief and frustration, and just remove the tank

[Momaru]

I managed to get it mounted with the tank in place but it's certainly not as easy. Pulling the tank's easy, even easier once you've got the bike stripped.

[ninja250]

Originally Posted by kkim

kc- hint w/ tie wraps... cut the tails off flush/square with the receiving end. your hands will thank you the next time you go in there fishing around close to the tie wrap ends. they can easily cut skin.

ask me how I know???

Oh snap! I'm graced with some of Kelly's wisdom by experience in my thread! j/k

All input appreciated, Thanks! Will do. I just cut that set of zipties off earlier too as I think I had them a click or two too tight. Probably doesn't need to be riding as tight as I think.

Originally Posted by currentsea

I've been able to remove my K&N air filter from the side without removing the tank, but putting it on is another story. I'd save myself the grief and frustration, and just remove the tank

Point taken.

Originally Posted by Momaru

I managed to get it mounted with the tank in place but it's certainly not as easy. Pulling the tank's easy, even easier once you've got the bike stripped.

Double noted.

You guys prefer with the header tubes from the stock airbox or without?

Thanks again guys. Any input is welcome when I'm over here wrenching on this thing alone. Never know when I might sight over something.

[kkim]

lol... after sticking your hands into equipment racks for over 30yrs, you learn a few things.... most times the hard way.

yes, after you are satisfied with the zip tie tension and placement, then go back and clean up the tails. That should one of the cleanup items you always do at the end of any job.

I wished I were bright enough to have invented the tie wrap. Amazing stuff with over a million different applications and soooo much better than using lacing cord, like the old days.

[ninja250]

If'n I had a bender I'd fab us up a number of brackets to rid of the zip tie.
To be honest I don't like that in there much. While I have this down time on my hands I should be figuring a way around that but budget is slim. Indeed the zip tie is all mighty.

I've seen a 6" wide bender at Harbor Freight I think and some 1-2mm thick aluminum panel and the problem would be solved. It's on the to-do list..

I also noted you lifted that harness off the carb with a zip tie too, and did the same on my bike.

[randomwalk101]

1) you don't have to use that zip-tie to hold the carb...I've been running without it for over a year or two now...no problem. I use BMC pods filters though but weight should be the same.
2) Jet your carb with 110 mainjet and 3 washer under needle and go from there..stock needle should be fine..save you tons of money from getting the "kit".
3) drill a little hole on each slider with a #70 drill bit...really helps with throttle response. Be very careful when you put the diaphram back in...it'll rip if your cover pinches it (big money).
4) do the throttle mod with some pcv pieces or zipties while you're at it.
5) don't forget to synch the carb when you put it all back together...adjust idles mixtures then synch carb AGAIN after everything is tuned.
6) drop the 15 teech sprocket in front and 43 in rear (stock is 45 right? can't remember anymore).

should be good for awhile unless you want exhaust and all that craps

[ninja250]

Cool, thanks for the tips dude.
I still want to get that Scott's Damper when I can! It's so expensive I might as well buy the welder too at Home Depot for half the price of the damper to weld it on

[ninja250]

Woo! Looks like I'll make the Socal ride this weekend. My pod filter showed up nice and early
Although it has a couple dents in it like it's been banged up a bit, it's just an air filter. Dude's shipping was like 48 hours over a Sunday!
I didn't know Summit sold bike filters on ebay! I used to buy Honda parts from them

Extra Ducati well nuts on hand now too.

[ninja250]

Here's what I ended up with for the filter "hanger".
Piece of coated coat hanger and a screw.
I like drilling holes in stuff in case that wasn't apparent by now
Got me in more trouble than done me good most of the time though.

That filter sure looks spankin' coming right off the carbs like that. Think I'll leave it that way. Can always try the header tube later too, I suppose.

[ninja250]

Woah! She's extremely lean now. haha No big surprise.
She wouldn't make it above 7,000 rpm though which was kinda surprising.
I take it that it's probably not good to run it like that for long.

Time to add another shim to each needle and rejet so she can drink some fuel.
Darned if I don't have any jets on hand yet. Time to work on that.

[kkim]

you need bigger mains than the stocks... 112s or 110s Keihin. didn't you read the thread on removing the airbox?

[ninja250]

Originally Posted by kkim

you need bigger mains than the stocks... 112s or 110s Keihin. didn't you read the thread on removing the airbox?

Yes I knew I'd have to change them out, just wanted to see what would happen without them.

I think I can tape up the air filter some until the jets get here.

[Momaru]

I've got a spare #70 drill bit on hand if you'd like it mailed to ya. Got a pair of 'em for marginally over shipping price when I did mine. Managed to drop the first one right after I got finished with it. Haven't seen it in months despite spending 20min fishing around for it. Just glad I wasn't working over the carbs for the drillin'. FWIW I'm using the stock runners on my K&N, but it still feels a little wobbly even with zipties cinched down, so may pull the runners. I know someone esle on the forum was passing theirs around but I've no idea where it's run off to.

If'n you get a chance would you mind measuring the depth of those stock runners from the gasket where they enter the airbox to the end, as well as the depth of the K&N. Been bugging me how much clearance they have off the back wall of the filter pod. If not, it's no big deal; can do it next time I do a rejet.

[ninja250]

Sure thing. Will pop them out and get a measurement for you tomorrow.
I think the filter fits so well without the runners I'm just gonna "run it" without them.

Ordered the Factory Pro jet kit. There went another $100.

I think I was going to save the filter for upgrade set #2 with the exhaust and jet kit but decided to do the filter after yanking the carbs for the first time because the stock airbox is ridiculous. Couldn't bring myself to put that sucker back in there. Think that's when I ordered a filter and forgot about the jets, and thus how I ended up where I am now.

[Momaru]

Haha, yeah. I remember the first rejet I did. Woefully unprepared despite reading related info. It's a hassle now but you'll thank yourself later for just doing the rejet/airbox pull now while you've got the bike apart.

As for spending $ on the bike... I know that feeling. My girlfriend just got me some protons for a late Xmas gift and I just shelled out for Woodcraft clip-ons and Shogun sliders as projects to stave off the need to ride in sub-freezing temps. As such, my wallet is a few Franklin's lighter. Will definitely be using your pointers/experience on the Shogun project.

[ninja250]

Well, a new day for modifications. Morning folks.
Will measure those runners for you Paul as soon as the sun pops up. Don't seem to sleep as well as I used to.

Good thing I didn't zip the fairings on when I put the air filter on and tested it last night too. Just the tank and seat. I guess I'll pull the tank and seat and filter again and tape it up some to close off the air flow and see if I can "tape tune" me a rideable bike for this weekend until that jet kit comes.

If they're quick about it at Factory Pro, they could have it to me in 2-3 days.. in time for Friday and I could slap the new jets in for Saturday. That would be nice but no hurries. Thinking like this is how I get ahead of myself on the jet kit in the first place.

I remember upgrading the air filter on my pocket bike back in the day and then it used to bog like crazy. Sucker just needed some new jets! lol

Oh yeah the reason I just sprang for the whole jet kit is 1) I wasn't sure about where to order a pair of 110's just yet and 2) will be running stock exhaust until I get that yosh on here. The Factory Pro website says the kit includes jets for no airbox, stock and aftermarket exhaust. Perfect!
Pretty sure I picked the right one, just gotta hope I receive the right one. Thanks for the info guys.

[ninja250]

Few things to address.
First off, Got a measurement on the runners for Paul into the airbox. Looks about like 55mm, so 2"-2.2" or so.




Next up I tried taping the air filter. Waste of time. I believe the runners have something to do with that. Makes perfect sense. Taping the filter without jetting but using the runners might work. But why waste my time, I'll just wait for the proper parts to show up there.

Regardless, here's pics of my futile attempts. haha






She ran the same like that as with out tape. Pointless..

..and for the highlight of the day..
The saweet brake lines showed up! No pads that were supposed to be in the same order but was already notified they are on the way too. Also my red ebay pegs! Give me something to do until the jets show up. Fingers crossed the show on Friday! They will be shipping from California. I paid tax on them!

[sixer]

nice break lines NIN must have - eventually
whats better stock front rubber or ebay pegs- i read someplace you should file the ebay ones b'cause of slipping-
I dont mind the stock-

[ninja250]

Yeah nothing wrong with the stockers really. Maybe just a little spongy. Grip fine though.
Figured I'd give these a go at only $20. Don't feel like moving the pegs up any with rearsets so decided to try 'em.

they probably mean the rounded end portion.. no real grip on the end. A dremel or file would fix that right up. Or a knurling machine or something.

[Momaru]

Originally Posted by ninja250

Few things to address.
First off, Got a measurement on the runners for Paul into the airbox. Looks about like 55mm, so 2"-2.2" or so.

Thanks a bunch KC! The filter itself is about 75mm deep (according to the online specs) so that should be plenty of internal clearance, even without accounting for the flanges on the filter.

[ninja250]

Got the pegs on.
They do sag a degree or two, but I don't think the sag will be noticeable. If so, I'll do the penny mod, or put a screw in the peg where it touches the peg mount.

The ends are slippery as I thought they would be and as six pointed out.
No biggie, maybe some grip tape will do. If not, I'll file some grip into them.
They are also smaller diameter than the stock pegs and therefore likely harder on your feet by a small amount.

I thought about cutting them down even so the knurled part is the end of the peg. Would only lose a half inch or so and gain more clearance on the ground anyways.

I'll see if the tiny bit of sag bugs me. Here's some pics, it's really not much sag at all but it's there.

P.S..
I'm in love with these brake lines! The back one is extra short! It doesn't do the 180* bend like the stock brake cable does. Hope it works out OK! The front brake line should be fine. Fairly sure the back one will be too.

Peg base went on easy, didn't have to bend the springs, just pushed them down hard to get the pin through.







Stock peg on the left (bikes' right) and ebay peg on the right (bikes' left)

[ninja250]

Throttle twist reduction modification.
Need to shape up the spacer a little more.
Not sure I'll like this mod but I'll try it anyways. If I feel any binding I'll be removing it immediately.

[ninja250]

After shaping up the ring some and fitting it (above pics were not final shape), the reduced throttle was nice!
Only problem was I had binding and no throttle return

Had to take it out. It got eaten up in there. Will try again later..