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Old January 7th, 2020, 11:53 PM   #1
memphisninja
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$150 Ninja 250 Build

Picked this up on FB for $150, only has 2300 miles on it and is in damn good condition besides missing some parts (luckily I have most of the parts. Was used as a parts bike, I plan on making it into a street fighter bike, but I can't make up my mind because the plastics are in good shape, just needs painting. The bike was missing a fuel petcock, ignition key, gas cap, upper triple tree, carbs,

Here is what I plan on doing.

Clean the bike and every nut, bolt, wire, plastic, etc. very thoroughly.

Order new Pirelli MT75 tires, new battery, fuel petcock, and a gas tank bracket

Re-grease and inspect the swing-arm bushings, suspension linkage bushings, new wheel bearings, new brake pads, clean the chain and oil (still good, just dirty as hell), and replace sprockets.

Change fork oil, upgrade fork springs, inspect steering stem bearing, check alignment on forks and triple trees, install clamp style handlebars on triple tree, make a headlight bracket.

Inspect the valve train and adjust valves if needed, check timing, and change the oil. Not planning on doing too much as the engine looks in damn good shape and has good compression (185 psi on both cylinders).

Get the extra carbs I have rebuilt by Ducatiman.


So far here is what I have done...

I've ordered a K&N pod filter, 110 main jets, 40 pilots, 15T front sprocket, front master cylinder, new ignition, upper triple tree, and a Pirelli Mt75 120/80-16 rear tire.

I have removed the rear end to be cleaned and inspected. I pulled the old air box out, I removed the chain and sprockets.

I am hoping for this to end up being a very clean build and cheap build. I expect to keep the grand total under $600.





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Old January 10th, 2020, 08:19 AM   #2
dodgerdad
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Looks like a lot of fun work. Keep on posting updates!
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Old January 11th, 2020, 08:22 AM   #3
Snake
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Great project. I love that color.
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Old January 11th, 2020, 03:51 PM   #4
DannoXYZ
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Great project!

Shoot, too late! I have spare upper triple-clamp I could’ve sent you!

Be careful about spending too much on these builds. Sum of all little parts here and there could’ve gotten you running EX250 already assembled.
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Old January 12th, 2020, 04:00 PM   #5
memphisninja
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Quote:
Originally Posted by DannoXYZ View Post
Great project!

Shoot, too late! I have spare upper triple-clamp I could’ve sent you!

Be careful about spending too much on these builds. Sum of all little parts here and there could’ve gotten you running EX250 already assembled.
So far I am only in $445 grand total ($150 for the bike, $60 in gas to get it, and $235 in parts so far.) I sure do appreciate it though!

Here is an update and some more pics.

So I made my own custom 1/4 fairing with the touring windshield. I still gotta fabricate some lower mounting brackets, but it should be fairly easy, I was thinking about some metal straps. Anyway, in the pictures it's just mocked up, so there is still some gaps, but that will go away once I make the proper brackets and get some stock mirrors back on.

As far as the rest of the bike goes, I installed a upper triple tree, got my new pirelli mt75 rear tire in,installed throttle cables, installed handlebars and controls, installed foot peg brackets, installed fuel petcock, organized carbs and parts so it can be cleaned, got my K&N air filter in, got some bigger jets for it, and I sealed up the bolt holes on the gas tank.

Not too much left. I just gotta get a front tire and get tires mounted and balanced, clean,install, and adjust the carbs, install a battery, re-grease the bushings, re-torque all bolts to spec ,valve adjustment, oil change, bleed brakes, install headlight bulb, install stock mirrors, and clean and oil the chain. Should have all of this done by next weekend. I plan to spend no more than $700 grand total. But when I am done I should have a Ninja 250 worth double that.





















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Old January 12th, 2020, 05:15 PM   #6
DannoXYZ
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Custom fairing!! That’s awesome!!
Can’t wait to see how this turns out!
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Old January 14th, 2020, 02:43 AM   #7
Singh2jz
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NICE!!!!

Looking forward to watching the progress of this build!!
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Old January 16th, 2020, 11:50 PM   #8
memphisninja
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Here is another update.

I got the ignition installed, gas cap, fuel petcock, throttle cables, upgraded power wires to 4 gauge (ground, battery positive, and starter positive), new Accel 8mm coil wire, mounted and balanced Pirelli MT75 120/80-16 rear, and the front end has been re-assembled and re-torqued to specs.

I have a carb set, front tire, sprocket, battery, spark plugs, and brake pads on the way. Once I get all of that installed and the bike running, I'll start focusing on the suspension. I am gonna use a 08+ rear shock and EX500 springs with 15w oil for the fork springs. If anyone has either of those LMK I would be interested in purchasing.





























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Old January 17th, 2020, 07:38 AM   #9
gantt
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you can generally find a gsxr shock on ebay for 30 bucks or less. i've bought two now and both cost about 25 bucks shipped
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Old January 20th, 2020, 12:20 AM   #10
memphisninja
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Ok guys, here is another update. I have the rear end completed. Here is what was done. Everything was really good shape on the swingarm, just cleaned up, regreased, and then reassembled. Pretty easy and straight forward.

Cleaned and regreased swing-arm, balanced wheel statically, cleaned chain, clean and regreased Unitrack linkage bushings, adjusted chain, aligned rear wheel, cleaned wheel, cleaned shock, and torqued all bolts to specifications.

Should have this done by next weekend. Just waiting on a few more parts. So far my grand total investment is right at $600, all I really need left is a battery, fork springs, fork oil, rear sprocket, and a headlight bulb.

































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Old January 20th, 2020, 06:54 AM   #11
jkv45
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One suggestion - shim the cush drive if you haven't -

https://faq.ninja250.org/wiki/How_to...the_cush_drive

Smooths out the on/off/on throttle transition. They typically are extremely loose.
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Old January 20th, 2020, 03:39 PM   #12
memphisninja
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Thumbs up

Quote:
Originally Posted by jkv45 View Post
One suggestion - shim the cush drive if you haven't -

https://faq.ninja250.org/wiki/How_to...the_cush_drive

Smooths out the on/off/on throttle transition. They typically are extremely loose.
Thanks, I completely overlooked that!
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Old February 16th, 2020, 06:25 PM   #13
memphisninja
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Name: Spencer
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Well I have it completed... Gotta get it painted now. I decided to run it open frame in the rear and tuck all of the electronics away and I plan to install a LED tail light. So far it runs fantastic with the K&N pod filter. I have 110 mains, 40 pilots and 1 shim on the needles. The carburetion is damn near perfect (just a tad lean at redline). It idles extremely consistently, and the low speed-mid-throttle is very smooth. I'll post some more pics later. Here is a video and some pictures for now.

https://www.facebook.com/spencer.mit...2893596293557/






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