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Old May 31st, 2011, 01:05 PM   #1
cerberusrex25
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99 Ex 250 project Cafe/streetfighter, The build thread.

Well, I decided t man up and post a build thread. I bought it for basically nothing from a friend and have added parts big as small over the past 2 years. basically it was a frame with a title and a bunch of parts, had to buy an engine in 2 pieces from 2 sellers which together makes up at a nicely 1700 mile engine.

Is taken a lot of blood sweat and tears but is finally shaping up into a nice looking machine.

How it all started






























Some progress:





Assembled the front fork and mounted the wheels in place(place holding until I get some new parts).







and what I want it to look like:


.


I'm currently doing a top end rebuild and carb cleaning, so far is a roller and finally got around to installing an ALL BALLS stem bearing upgrade set. hope to be done soon and be riding by either the season's end or next season.



I did some work yesterday and finally installed the radiator(after extensive cleaning) my new engine mounts(ACE is my new favorite place , loads of metric bolts and cheap) and the center stand, I can finally work on it with ease.

here is she as she stands:



Also I worked on sanding my tank and was planning to leave it bare metal, but my Dad had a goofy moment and this happened:



He felt so bad for the rest of the day, but I told him not to worry about it. He then proceeded to go behind my back and call a mutual friend who does body work and offered to pay for it. I love him so much.


Well, here is the beginning, feel free to ask questions, comment, share , discuss, send donations to me , etc.

Hope you guys like it and stick around to see the results.
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Old May 31st, 2011, 01:19 PM   #2
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It is starting to look like a bike already. Can't wait to see how it looks in the end.
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Old May 31st, 2011, 01:45 PM   #3
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Old May 31st, 2011, 02:30 PM   #4
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Old May 31st, 2011, 02:59 PM   #5
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Looking forward to seeing this progress, good luck
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Old May 31st, 2011, 03:42 PM   #6
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That's funny. Looks just like my fighter build. Even has the same color tank and wheels. It will be cool to see how they turn out differently! I'm not posting a build thread until it's mechanically sound though.

If the tank is being repaired, you should have them shave the fairing mounts at the same time.

What are your plans for gauges and rear cowl?
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Old May 31st, 2011, 03:42 PM   #7
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Looking forward to seeing this progress, good luck
Tony... looks like you and Dave have/will have a lot in common. Best of luck to the both of you.
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Old May 31st, 2011, 04:31 PM   #8
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That's funny. Looks just like my fighter build. Even has the same color tank and wheels. It will be cool to see how they turn out differently! I'm not posting a build thread until it's mechanically sound though.

If the tank is being repaired, you should have them shave the fairing mounts at the same time.

What are your plans for gauges and rear cowl?
Gonna find me some simple round tachometer and speedo,maybe find a way to get all the indicators into a small box in the middle. as for the rear cowl I'm still deciding to either build one from scratch or chop an existing cafe seat.

PS: the fairing mounts are definitely getting shaved and smoothed out.
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Old May 31st, 2011, 05:38 PM   #9
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Looking forward to seeing your build!!!!
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Old May 31st, 2011, 09:03 PM   #10
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Drew this tonight because I was bored and infatuated with the work of Radical Ducati( a shop from Spain)



Is a more definite concept of what I want.

Will upload a better one once Fb comes back on.
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Old May 31st, 2011, 11:27 PM   #11
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Are you going to chop the lower frame and bend it upwards at the swingarm mount?

Last futzed with by CynicalC; June 1st, 2011 at 04:45 PM.
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Old May 31st, 2011, 11:59 PM   #12
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I've seen quite a few cafe racer seat cowls recently that were fabricated from old gas tanks, usually a slim model from a '70's or '80's Jap bike.
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Old June 1st, 2011, 07:39 AM   #13
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Quote:
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Are you going to chop the lower frame and bend it upwards swingarm mount?
yeah that is the general idea.

Quote:
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I've seen quite a few cafe racer seat cowls recently that were fabricated from old gas tanks, usually a slim model from a '70's or '80's Jap bike.
Wow, that is actually interesting, I will be researching it.
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Old June 6th, 2011, 09:04 AM   #14
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wow.....keeping eyes peeled
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Old June 6th, 2011, 09:09 AM   #15
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Well this bike is honestly going to be yours and truly custom =p
Goodluck! Looking good already
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Old June 6th, 2011, 07:47 PM   #16
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Thanks guys, anyone know if the 2 wheel levers would fit this bike? also wondering about the current gen wheels fitting this ninja.
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Old June 27th, 2011, 11:36 AM   #17
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Bad news everyone, I was prepping my engine for that top half rebuild I intended to have done, and I found this:







I think this throws away my budget, I am so frustrated and don't know what to do about it.

Thoughts? I will truly appreciate them.

Last futzed with by cerberusrex25; August 3rd, 2011 at 12:06 PM.
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Old June 27th, 2011, 11:42 AM   #18
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If you are not capable of doing the lower end your self I would go buy a running motor should be around 700
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Old June 27th, 2011, 12:48 PM   #19
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My opinion, (bearing in mind I'm new to these bikes, and only just rebuilt the top end on mine), is that mainly rust I can see in there? If it is just the head gasket that has leaked water into the cylinder, don't panic quite yet. Lift the barrel, if that piston is stuck in the bore, pore some paraffin or diesel down the bore and leave it a few days to free it. Be careful that you don't drop too much crud and stuff down into the crankcase when you lift it. Always a good idea to push some rags into the opening as you lift the barrel.
It's possible that the bore can be honed by a local machine shop, or even using a hone attachment yourself. Get some new rings, and clean the piston up.
You must get the head and barrel checked for flatness on the mating surface too, it may be that a warp caused the problem in the first place.

Of course, I'm just going by what I can see in the pictures, is the piston actually damaged ?

Good luck, and like I said, don't always expect the worse, (if I had with mine, it would be in the canal by now ).
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Old June 27th, 2011, 12:51 PM   #20
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Taking another look at the pictures, I guess the motor may have been left out in the open with no spark plug in the hole, the resulting rusty mess can often be less trouble than at first it seems.
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Old June 27th, 2011, 10:26 PM   #21
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Thanks Tony, I think you might be correct. The piston seems to be a little cruddy but generally OK, I don't really see any major damage aside from the rust. if it helps it had a bunch of solidified crud in there too, I think your theory about the no spark might be quite accurate. I wont get discouraged and clean it up and buy some rings and take it to my mechanic.
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Old July 8th, 2011, 10:02 AM   #22
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Got this little treat today thanks to CynicalC:



they fit like a glove, this is so I can get her street legal and running. The engine drama continues.
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Old July 8th, 2011, 06:13 PM   #23
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All mounted up just to see how it would look, now I need to fix that damn engine.

Last futzed with by cerberusrex25; August 3rd, 2011 at 12:08 PM.
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Old July 11th, 2011, 08:53 PM   #24
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worked on my engine today, here is the result after 2 hours of wiping and brushing it with gasoline



Also piston was not stuck, just gunky. Outlook is looking better.

Last futzed with by cerberusrex25; August 3rd, 2011 at 12:07 PM.
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Old July 11th, 2011, 08:58 PM   #25
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Quote:
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If you are not capable of doing the lower end your self I would go buy a running motor should be around 700
Yeah, I paid 300 for the bike, and had invested another 400/500 on it. I tried the whole gunk be gone think and it seems it was only surface stuff, will inquire on getting it bored 1 micron or so just so is all smooth and stuff.
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Old July 12th, 2011, 09:57 AM   #26
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Someone suggested I use a dremmel and a brass brush, is this safe? I dont want to mess up the chamber and have to end up changing the sleeve.
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Old July 12th, 2011, 10:20 AM   #27
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Use a diamond hone
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Old July 12th, 2011, 01:06 PM   #28
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I would, if I had the skill and knowledge to bore it, I take it a brass brush will be a safe way to get rid of the rest of the loose grime that is still there.
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Old July 12th, 2011, 03:24 PM   #29
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It would be, though you look like you got most already ...
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Old July 12th, 2011, 03:45 PM   #30
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I did, is just it has a few left over pieces of crap in there. My father keeps telling me not to worry since those are just carbon deposits and I might end up messing it up.
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Old July 12th, 2011, 03:47 PM   #31
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I'd say he's right, looks fine to me, told you not to worry too much the other week ...............
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Old July 12th, 2011, 03:51 PM   #32
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True that, I guess I'm such a Worry Warren when it comes to the unknown. I believe this will be a green light on the rebuilt? I want to make sure before taking it to the mechanic this Friday.
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Old July 12th, 2011, 09:59 PM   #33
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Looks good! Glad those parts worked out. I got the check from the post office yesterday. I feel bad cashing it. It looks so antique. I bet they had to dig it out of a warehouse basement somewhere hah.
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Old July 12th, 2011, 10:02 PM   #34
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Looks good! Glad those parts worked out. I got the check from the post office yesterday. I feel bad cashing it. It looks so antique. I bet they had to dig it out of a warehouse basement somewhere hah.
HAHAH, jolly good, the smell of olde money, BRILLIANT!!!, glad to hear you got paid man. Pleasure doing business with you.
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Old July 23rd, 2011, 04:54 PM   #35
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So thanks to Bosgarage57 and CZroe I finally tracked down and integrated tail light kit. bought it today and is finally in transit. As the day grew hotter and my idle mind kept running I decided to Do Work and finally chopped that ugly fender.

Here is the result:







And the carnage that preceded it:


Last futzed with by cerberusrex25; August 3rd, 2011 at 12:10 PM.
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Old July 23rd, 2011, 05:21 PM   #36
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is that the stock position for the regulator/rectifier? build is looking good... did you resolve your piston/cylinder issues?
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Old July 23rd, 2011, 05:25 PM   #37
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Not sure about the rectifier, I took it off to wash that plastic pan is attached to, so I might've put it on backwards. As for the piston, yes it turns out it was not stuck and it was all surface grime that came from the upper side due to it not having a sparkplug in it and left outside by the previous owner, I went at it with a brass brush and some 600 grit sandpaper with oil and is good to go. will be taking it to the mechanic the week after next one.
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Old July 24th, 2011, 01:11 PM   #38
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Hey I just realized I still have those 4 little tie-down clips that go with the tail piece. Do you want me to send them to you?
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Old July 24th, 2011, 04:19 PM   #39
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HAHAH, no worries dude, I had some that came with the bike. Thanks for worrying though.
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Old July 25th, 2011, 11:14 AM   #40
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Quote:
Originally Posted by cerberusrex25 View Post
Gonna find me some simple round tachometer and speedo,maybe find a way to get all the indicators into a small box in the middle. as for the rear cowl I'm still deciding to either build one from scratch or chop an existing cafe seat.

PS: the fairing mounts are definitely getting shaved and smoothed out.
My suggestion for the tail cowl is use a busa, tiller, or srad seat cowl as a base.

They have the shape you want and can be pretty cheap seeing as you can make due with a damaged one.

There may be some other ones that work too.

I'm in Centreville too btw, off Compton, if ya need a hand with anything

And I'm the same Bob138 from customfighters

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