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Old May 9th, 2016, 04:03 PM   #1
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17" wheels on pregen, how to

Did 4 conversions this spring, 3 using newgen wheels and 1 using EX 500 wheels. I didn't have much to do with the 500 conversion, but I'm sure rubbersidedown would answer questions on that conversion. This how-to is using the newgen wheels.

The front wheel is pretty straight forward, used all newgen spacers and speedo drive. Axles are the same. Had to make spacer washers on both sides next to the forks, about 4.5 mm each. I ground them to fit without putting any force on the forks and to center the wheel between the forks.
DSCF002.JPG

Made a bracket to weld to the existing caliper mount so it would work with the stock newgen disc, newgen disc is 30 mm bigger in dia.
DSCF0013.JPG

I drilled and tapped the bracket to bolt to the stock position on the fork. While bolted in place, I positioned the pregen caliper on the disc and held it in place with a little pressure on the brake lever and rotated the caliper against the new bracket and tack welded it in place. Then took the caliper apart and welded it solid, painted it and put it back together.
DSCF001.JPG

Rear wheel was a little more involved, used the pregen sprocket hub and cush drive rubber and spacers. If you use the newgen rubber you'll need to cut off the little rubber bridges that hold the cush rubber together to make clearance.(sorry no pics)

The spacer inside the hub, between the hub and wheel, needs to have 3 mm removed to center the wheel.
DSCF0001.JPG

Take the 3 mm off the wheel side of the spacer, this must be a square cut or it will put uneven pressure on the bearings.
DSCF0004.JPG

The nose on the wheel that holds the O-ring between hub and wheel needs to be cut down so that it will just hold the O-ring in place (about 3 mm)
DSCF0009.JPG
Just below the O-ring in this pic, is factory machined, and just below the factory machining needs to be machined or ground with a die grinder (above the cush drive spokes) to make room for the hub to slide on the extra 3 mm

The newgen wheel is still 11 mm to wide at the axle, so I took 11 mm off the outside of the rear brake caliper mounting bracket, this also must be a square cut or the caliper won't fit the disc squarely and will bind and twist when the brake is applied.
DSCF0006.JPG

DSCF0007.JPG
The newgen disc will now be positioned properly though it is 10 mm smaller in dia. than the pregen disc (no they won't interchange) which is only 5 mm different where the caliper mounts, hasn't been a problem yet but haven't been to the track yet. I don't foresee a problem, but if someone is worried the EX 500 rear disc is the same dia. as the pregen with the newgen bolt pattern. Clean it all up and mount it on the bike, you'll need to remake the rear brake anchor or tweek it over a bit (that's what I did) and run a drill bit through so the bolt won't need to be hammered in and out.
DSCF003.JPG
DSCF004.JPG
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Old May 9th, 2016, 04:33 PM   #2
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Old May 9th, 2016, 06:58 PM   #3
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@Alex this should be a sticky in the PreGen tech.
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Old May 9th, 2016, 11:03 PM   #4
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Quote:
Originally Posted by Z1R rider View Post
Did 4 conversions this spring, 3 using newgen wheels and 1 using EX 500 wheels. I didn't have much to do with the 500 conversion, but I'm sure rubbersidedown would answer questions on that conversion. This how-to is using the newgen wheels.
Having put (aftermarket) NewGen wheels on my 500, I can say that the parts are nearly identical between the two. The spacer in the front wheel between the bearings is a different length. The speedo tabs on the 500 wheel are on a separate piece that snaps in, while the NewGen has them as part of the wheel itself, so the speedo drive is slightly different too. Other than those minor differences, it was a direct swap.

If there are any doubts about the condition of the bearings, you can get a set of All Balls bearings (25-1444 front and 25-1234 rear) for about $25 total from Amazon.
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Old July 12th, 2016, 01:38 PM   #5
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Thank you for this write-up.

Do you remember the dimensions of the front brake bracket? I'm in the same boat except I'll be using newgen caliper.

Also, does your fender rub with the bigger wheels?
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Old July 12th, 2016, 01:57 PM   #6
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Old July 12th, 2016, 05:13 PM   #7
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Quote:
Originally Posted by UFOmoplata View Post
Do you remember the dimensions of the front brake bracket? I'm in the same boat except I'll be using newgen caliper.

Also, does your fender rub with the bigger wheels?


I just made the bracket as I went, no real measuring or blueprint. Not likely to be the same as a new gen anyway. I'm running a Bridgestone RS10 110/70 without rubbing, trial fitted with a Metzeler 120/60 and that cleared also, #2 son has a 120/70 Michelin Pilot Power and had to move the fender up to clear. Even though the rim is an inch bigger the tires have shorter sidewalls than the 16" tires so for the most part your not changing the overall circumference. In fact the Metzeler 130/90 16 is 1-3/4" more in circumference than the Bridgestone 140/70 17 that I have on the rear now.
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Old July 12th, 2016, 07:29 PM   #8
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Okay, I'll have to borrow someone with welding skills to whip up a bracket like yours.

I'm running a 110/70 Kenda, so I should be good then.

Thank you.
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Old October 23rd, 2019, 08:56 AM   #9
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Just throwing it out there for a note as this is a sticky post.

Ninja ZZR250 (EX250H) were sold in Canada with 17 inch wheels. 100/80 - 17 Front and 140/70-17 rear.

I have got a 2007 model. From what I can tell the parts that are related to the wheel somehow, i.e. brake rotors are the same as on newgen 250.
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Old October 23rd, 2019, 10:52 AM   #10
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Are centre of spokes angled laterally on ZZR250 wheels? So they form Z cross-section? Do you know front axle diameter?

I think they're same 17" wheels as 2nd-gen EX500.

I've actually used EX500 17" rear-wheel in new-gen rear-swingarm on my pre-gen 250. Along with new-gen brake, linkage and shock.
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Old October 23rd, 2019, 12:28 PM   #11
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Quote:
Originally Posted by DannoXYZ View Post
Are centre of spokes angled laterally on ZZR250 wheels? So they form Z cross-section? Do you know front axle diameter?

I think they're same 17" wheels as 2nd-gen EX500.

I've actually used EX500 17" rear-wheel in new-gen rear-swingarm on my pre-gen 250. Along with new-gen brake, linkage and shock.
Danno, yes they have a Z cross-section, indeed. I do not know the axle diameter but I am going to take the wheels off soon to change the tires, I will measure it and post it here.
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