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Old March 25th, 2015, 07:18 AM   #1
Butch
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Cafe Racer Project - 04 Ninja 250R

I've started a cafe racer project on a 04 ninja 250.
I'm feeling the need to share this experience.
So about me. I have a disease that makes me do everything and anything myself. I have issues with paying someone to do something that I can do myself.
Well, on to the project. I was browsing the web and ran into bluecollarbobbers site and saw the ninja cafe racer.

OMG! gotta have one. So it all starts from here.
Started browsing Craigslist and eBay.
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Old March 25th, 2015, 07:25 AM   #2
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Welcome Butch! there are a few builds on this site for cafe bikes, I am in the middle of one myself. In the end, do what you like to your bike, just keep it safe.
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Old March 25th, 2015, 07:36 AM   #3
Butch
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Cafe Racer Project

I found a frame and engine from a guy that parts out motorcycles.
The frame came with a clean title. The matching motor has a holed piston.

Now I need a parts bike.
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Old March 25th, 2015, 07:51 AM   #4
Butch
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Cafe Racer Project

Found my parts bike. Missing some parts but it will do. Wasn't able to test it as the battery was dead. It's ok though since was dirt cheap.

Time to dedicate a lot of hours into this project.
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Old March 25th, 2015, 08:00 AM   #5
Butch
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The Tear Down

Heres a couple pics of the tear down. This turned out to be super quick n easy.


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Old March 25th, 2015, 08:08 AM   #6
Butch
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Engine Teardown

Heres the engine teardown. A little more complicated but doable.






I believe I am All In. No turning back.
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Old March 25th, 2015, 08:25 AM   #7
Butch
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Side Tracked

I realized if I'm doing a bike build it shud be something pretty so heres a necessary side project.

I think u can guess wat it is. All homedepot material except electronics from eBay.













Under $300. But doing 1000+ Rivets was not worth it at all!
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Old March 25th, 2015, 08:35 AM   #8
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I'd like to see how that dangling receptacle is wired in your box lol
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Old March 25th, 2015, 08:43 AM   #9
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Quote:
Originally Posted by Butch View Post
I realized if I'm doing a bike build it shud be something pretty so heres a necessary side project.

I think u can guess wat it is. All homedepot material except electronics from eBay.
a giant toaster oven for oversized toast?
or perhaps a powder coat oven.
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Old March 25th, 2015, 09:22 AM   #10
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I'll try to take a pic inside that panel. hehe. I paid electrician to put a 200AMP service but I wired the rest of the house. I was out of space for another 220 plug so I swap out that custom extension plug with a breaker on the end with the dryer breaker when I need to cook parts.
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Old March 25th, 2015, 09:26 AM   #11
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Hah. Not the most elegant solution but it works. I just thought you had it spliced in pre-meter.
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Old March 25th, 2015, 10:02 AM   #12
Butch
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Old Toy VS New Toy

I dont think hes happy about my new toy.

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Old March 25th, 2015, 10:20 AM   #13
Butch
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First Attempt at Playing Chef

Here's my first batch of baked goods.
First tried with a craftsman gun but that did not work at all.
Not enough electrical charge for big metal pieces like these so I ran to harbor freight and luckily they had their gun in stock.













Favorite color is Green btw.
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Old March 25th, 2015, 12:34 PM   #14
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Stripped!

The frame stripped. At this time I did not realize how much more prep work it needed.



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Old March 25th, 2015, 12:42 PM   #15
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Assembled Lower End

Too excited to finish the bike I decided to mount the engine on the other frame and attach the top end jus to see how it looks.
Thats my boy Rocco. He seems interested now.







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Old March 25th, 2015, 01:05 PM   #16
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Rocco

Nothing excites this guy. I thought this bike build would do it.







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Old March 25th, 2015, 01:13 PM   #17
Butch
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Frame Covers and Forks

The frame and lower forks are done. In gold. ermm.. still unsure about that color but too late. Covers are done in Transparent copper. I get all my powders from prismatic btw.



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Old March 25th, 2015, 01:41 PM   #18
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That's some awesome detailed work Butch!
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Old March 25th, 2015, 01:47 PM   #19
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Quote:
Originally Posted by cuong-nutz View Post
That's some awesome detailed work Butch!
Thanks. I'm trying to post all that I have done so far so I can catch up to the current status of the bike but it's almost there.
I have a lot of parts arriving this week including the cafe kit from bluecollarbobbers that is out for delivery today!
Lots of stuff to do this weekend.
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Old March 25th, 2015, 01:58 PM   #20
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Any ideas as to what are you going to do with the area that covers the airbox/carbs?
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Old March 25th, 2015, 02:13 PM   #21
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Quote:
Originally Posted by cuong-nutz View Post
Any ideas as to what are you going to do with the area that covers the airbox/carbs?
The kit includes a triangular piece that covers that area.
I have my mind set on getting that kit installed this weekend.
Just got a txt from gf and told me that it was delivered but the boxes look like they've been to a soccer game. I hate U Pricking Shipping company.
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Old March 25th, 2015, 02:48 PM   #22
Butch
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Favorite Color = Green

Tank Powdercoated Emerald Frost Over Black.
Had to go easy on top coat else it would turn into a light olive gold green.
Good thing I tested on a sample first.







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Old March 25th, 2015, 02:53 PM   #23
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I was looking at that kit too and it runs for about $1800. Keep us updated. Love the progress so far.
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Old March 25th, 2015, 02:56 PM   #24
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Engine Complete

Gaskets came in so I was able to complete the engine assembly.
Seated the valves and adjusted the valve clearances.
This was my first time ever playing with engine internals.
Lots of googling and forum reading occurred during this time.







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Old March 25th, 2015, 03:16 PM   #25
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Up to date

Now heres where the bike is as it sits in my garage today.
Didnt get to take much pics as i was soo tired from putting it together.
I filled it with oil and coolant and did a test start. nothing happened.
sprayed some or not some but i think a lot of that starter spray n it it started.
scared the hell outa me cuz it jus revved so friggin high i thought it was gonna blow. now i know to jus spray jus a lil bit.
Trouble shooted a bit. Pulled the vacuum hose from carb and applied a vacuum to it n tried starting again. it turned on and stayed on but there was gas flowing from the overflow tube. I need to do a bit more research as to wat the prob is but ill figure it out. getting bowl seals and new jets in this week. gonna super clean the carb again. enough talk. heres the bike as it is today. i really hate that evap can.



Oh n i did the wheels in copper.
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Old March 25th, 2015, 03:22 PM   #26
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I noticed a coolant leak. about one drip per 4hrs. hehe. rite under the water pump. i realized that i dont ever remember torqing that down so i drained the coolant and inspected it. i pulled the pump from the case and oops! oil gushed out. newbie mistake i guess. now need more oil too.
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Old March 26th, 2015, 09:42 AM   #27
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Kit arrived

Kit came in but did not get a chance to fully play with all the new parts.
Heres a pic of the seat. the one item I was worried about because it was named natural leather and i wasnt sure it would fit all my colors. well it matches the copper.

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Old March 26th, 2015, 11:54 AM   #28
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Quote:
Originally Posted by Butch View Post
Kit came in but did not get a chance to fully play with all the new parts.
Heres a pic of the seat. the one item I was worried about because it was named natural leather and i wasnt sure it would fit all my colors. well it matches the copper.

Nice. Looks good. Doesn't this kit use the stock speedometer gauge? Looks like the bike you picked up didn't come with that.
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Old March 26th, 2015, 11:58 AM   #29
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Quote:
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Nice. Looks good. Doesn't this kit use the stock speedometer gauge? Looks like the bike you picked up didn't come with that.
It actually did but was not attached to the bike.All the stuff that fell off the bike when the guy crashed it was in a box.Gauges in good condition I think. Hopefully. I know the tach and N lights work.
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Old March 26th, 2015, 02:15 PM   #30
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what. how .what. how is this happening so fast, ...cocaine?
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Old March 26th, 2015, 02:39 PM   #31
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what. how .what. how is this happening so fast, ...cocaine?
I would never touch anything like that...
Maybe I should. My pain relief has been Dos XX. It's not working as good as it used to.
I actually started this project end of Jan and was browsing my photos of all the work that I did. Thats when I decided to post it here up until the last pic you see here.
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Old March 27th, 2015, 07:34 AM   #32
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Test Fit

I hacked the frame again. This time to propper length using the guides ftom the kit.
Mounted the new front tire and old rear tire. That was not fun.
Spent about an hour trying to find my tire inflator attachment and never found it.
Moved on to test fitting the seat supports. All went smoothly.



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Old March 28th, 2015, 05:21 AM   #33
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Wow... Can't wait for more...
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Old March 28th, 2015, 05:38 AM   #34
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This looks great!
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Old March 28th, 2015, 07:10 AM   #35
Butch
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Seat supports

Thanks guys.

Coated and installed the seat supports last night. Trying to get a headstart on the weekend. Planning on having most of the kit powdercoated and installed and when my carb parts come in today i hope to have it running.

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Old March 29th, 2015, 06:25 PM   #36
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Kit Intalled. After a whole lotta f ups

So im too drunk too keep goin on this bike.
Time for walking dead.
Basically spent the whole weekend trying to fix the powder coating on the kit. I coated the kit sat morning. Basically wasted day cuz i over sprayed the top coat. It turned to a light olive green. Looked ok but did not match the tank. I recoated the base n sprayed the top coat while hot n it came out very textured. Like 60 grit sand paper. Looked really cool then slept on it. Woke up n decided to start over. Stripped all the pieces n redid it. Didnt get thru Intalling the rest of the kit. I jus wasnt happy with the green so i think it was worth the time spent to fix it. So enjoy. Here is the fruits of my labor. I personally think its pretty awesome. I still got a boner from it. Sorry. still drunk. Ran outta beer so i drank my gf dosaritas. Enough blabbler. here are the pics.











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Old March 30th, 2015, 10:49 PM   #37
Butch
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Instrument Cluster

Installed the guages.

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Old April 2nd, 2015, 07:01 AM   #38
Butch
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Rear Lights

I wish everyday was a weekend. With only 60 mins playtime after work I cant get anything done.
Gonna be another busy weekend.
Installing kn air filter pod.
Chop up air box.
Install jet kit. Sync carbs.
Then finish off the blue collar kit.

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Old April 2nd, 2015, 09:13 AM   #39
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Wow... you did all of it in two weekends? Holy cow...
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Old April 5th, 2015, 09:44 AM   #40
Butch
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Shes Done!

Bike is basically done. Jus need to break in the engine n adjust valves later. Took it for a spin around block and that kn pod filter sounds awesome. Very throughty sound.







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