Yakaru's Modification Fest

[Yakaru]

So odds look good that I'll be getting back my Ninjette this week; which means it's time to go on a mod fest! I figure I'll document my work here as things progress and maybe even turn this into a form of DIY if people think it ends up being useful.

Mods being done:

• -> Rejetting after installation of AreaP Exhaust + other mods (see below)
• -> Removing air filter box
• -> KLEEN Air system blocked off
• -> Carb Syncing
• -> Proton Flush Mount Signals
• -> Diode Mod
• -> Turn Signal Mirrors
• -> New Decals

Other things I'm doing:

• -> Chain Lube

DIYs I'm referencing:

Air Filter Box:
- http://www.ninjette.org/forums/showthread.php?t=11899
- http://www.ninjette.org/forums/showthread.php?t=78035
- http://www.ninjette.org/forums/showthread.php?t=11899

KLEEN Air:
- http://www.ninjette.org/forums/showthread.php?t=9948
- http://www.ninjette.org/forums/showthread.php?t=97700

Carb Sync:
- http://www.ninjette.org/forums/showthread.php?t=9754

Proton Flush:
- http://www.ninjette.org/forums/showthread.php?t=36477

Diode Mod:
- http://www.ninjette.org/forums/showthread.php?t=24500

Tools Needed:

• HERO FRH-07 Crimper/Cutter/Stripper
• Soldering Iron
• Narrow Flathead Screwdrivers (for carb jets)
• Milwaukee Offset Attachment
• Standard Toolkit items (screw drivers, allen wrenches, etc.)
• Swingarm stand

Supplies Needed:

• Waterproof/Adhesive-Lined HST, 1/4", 18"+ length (I got 48" x 2)
• 60/40 Rosin Cored Solder
• HC050 Connectors A good number of these, plus spare terminals.
• Stranded Wire (20 AWG, multiple colors preferable)
• Gasket Sealer
• Liquid Electrical Tape
• 2x Glass Bottles
• UL Hose
• 2x Rubber Corks
• 2x Vacuum Caps (3/16")
• 1x 4-way Vacuum T (3/16")
• Petroleum Jelly

Parts Needed:

• Emission Blockoff Plate
• K&N 62-1340 Vent Filters
• K&N R-0990 Norton Universal Rubber Filter
• Proton Turn Signals
• Turn Signal Mirrors
• Decals
• Swingarm stand spools

If anyone thinks I'm missing anything let me know, otherwise stay tuned for pictures and results

[menikmati]

You're getting Protons AND turn signal mirrors? wut...

[Jiggles]

Originally Posted by Yakaru

I figure I'll document my progress here as things progress and maybe even turn this into a form of DIY if people think it ends up being useful.

Where'd you get that idea???

Well have fun, you'll definitely want to get a rear stand, it makes everything so much easier

Also, are you getting the race system or the regular one?

[Yakaru]

Two reasons:
1. one of my mirrors was banged up in my crash, so I need to replace it anyway
2. I'm getting flushmounts for appearance, but I want the added visibility/safety with the mirrors in addition.

[Yakaru]

Originally Posted by Jiggles

Where'd you get that idea???

Well have fun, you'll definitely want to get a rear stand, it makes everything so much easier

Also, are you getting the race system or the regular one?

I'll put a rear stand on my list, thanks for the reminder.
The regular one -- long/quiet model.

[Jiggles]

Good choice

Have you heard a bike with the airbox removed and pod filters installed? It is very loud, I was quite surprised by how loud it is. If I ever got another ninja 250 I wouldn't yank out the airbox, I'd probably just pull out the snorkel. Actually try that first, yank out the snorkel and note the change in sound, then imagine that times 10 and thats what removing the airbox does.

Just a thought

[menikmati]

Originally Posted by Jiggles

Good choice

Have you heard a bike with the airbox removed and pod filters installed? It is very loud, I was quite surprised by how loud it is. If I ever got another ninja 250 I wouldn't yank out the airbox, I'd probably just pull out the snorkel. Actually try that first, yank out the snorkel and note the change in sound, then imagine that times 10 and thats what removing the airbox does.

Just a thought

Maximum brap brappin'

[Yakaru]

Guess who's bike is back Getting started first thing tomorrow, I had to walk to the shop to pick up the bike since none of my friends were available today -- 20 miles in leathers is not an experience I recommend.

[Ben M]

You walked 20 miles? In leathers? That's like 6 hours? I would have waited for your friends to be available

[Yakaru]

That would have been a couple of days, and I'd already planned to do my own repairs this weekend -- so walking it was. It was good exercise to boot; so long as I don't have to do it again :P

[Jiggles]

[Jiggles]

I'd like to rescind the image I posted earlier about your mental state. I have made a gif that more accurately describes the true nature of a person that would walk 20 miles in leathers.



I for one would never walk that far. and not just because I can only go 10 feet before collapsing

[alex.s]

Morbidly curious to know if Jiggles already had the weird banana porn on his computer or if he actually had to do a search for it.

[Jiggles]

Well @alex.s,

First I searched for "****ing bananas" and all I got was women ****ing themselves with bananas. BOOOOORRRRING. So then I turned on safe search and searched for "guy humping banana" and this was the prime contender. I clicked on the picture and nearly **** myself. Would you believe that the best picture of this very act I have described was actually not a picture at all? I was overwhelmingly happy that it was in fact an animated gif. I slapped some words on and here we are.

[alex.s]

Don't ever resume your medication.

[Jiggles]

Sure thing bud

[ZackoFF96]

LOL @ all jiggles expression

oh yeah how can i add words to a gif ?

[Yakaru]

So, long hard day of modding. About half way through this is what she looked like:

By 11 at night she was this far along:

So... looks like I have to work from home tomorrow and try to finish her!

[Jiggles]

Hmm, looks familiar.....

[Yakaru]

Another day of hard work has results!:


Threading needles!


Carbs being reattached


Back in riding conditions!

I ran her down a few car lengths in first and she purred great. Here's a status update:
Rejetting: new needles/jets (104s) placed, initial set on pilot jet (2 full turns out, IIRC). Haven't started actually jetting this.
Air box: removed. Done.
KLEEN: blocked. Done.
Carb Sync: not started yet.
Electrical Work: not started yet.
Visual Work: not started yet.

Leaving her in a "Street Fighter" look of sorts while I start working on the actual jetting and such, since taking the fairings on and off over and over would be silly, but I also have to get to work

Many many many thanks to @Momaru for spening HOURS on Skype with me and walking me through this (including repeated warnings when I was in the carbs to be careful with the diaphragm; which I obeyed). If I've screwed up my description here, or missed something, please chime in!

More to come~

[Jiggles]

You put in 104 dynojet mains? That's not nearly big enough, you're doing a K&N filter right?

[Yakaru]

Correct, K&N. Dyno/Jet Kit came with 104s, 106s, and 108s -- starting with the 104s, I suspect they will be changed.

[Jiggles]

It's better to start rich than lean. I suspect that 108's will be just about perfect for you. You have the street system right? Here is my dyno with the race system, this is with 108's and it was still lean



Well, it was kinda crazy, but it was lean nonetheless

Then I slapped in some 112 equivalents and baboom, too rich. Also needle in the 5th position which is why the bottom end looks like poop



So for the race system 110's will probably be perfect, for yours I'll bet 108's are right on the money.

[Momaru]

Yep, that's my bad. I'm running DJ108's at 1100' elevation, & on top of that mis-remembered the Keihin-DJ sizing conversion a lil (I know it's on the Jetting Database). Definitely doing 108s for the mains soon as we have time.

[Yakaru]

Interesting aside: We're getting some conflicting numbers regarding the 'stock' jets.
This page (the one I found) reports DJ102s are equivalent to stock: http://faq.ninja250.org/wiki/Dynojet...zes_conversion
But Momaru was using this page, http://www.ninjette.org/forums/showthread.php?t=10208 which reports stock is ~a DJ 96/98 or so.

[Jiggles]

Originally Posted by Yakaru

Interesting aside: We're getting some conflicting numbers regarding the 'stock' jets.
This page (the one I found) reports DJ102s are equivalent to stock: http://faq.ninja250.org/wiki/Dynojet...zes_conversion
But Momaru was using this page, http://www.ninjette.org/forums/showthread.php?t=10208 which reports stock is ~a DJ 96/98 or so.

Well stock is Keihn not dyno jet. If you look at the jets you pulled they have a small number on them that tells you the size

[Momaru]

That faq.ninja250.org page is built for the 2007 and older bikes.
I'll bet you dinner next time we're in the same location that you pulled a Keihin 98 off your bike last nite, which is ~DJ96.

[ryan.chin]

This is a bad ass thread. A+

[Yakaru]

In a holding pattern at work so I thought I might post some of the 'interesting' things we've run into so far:

1. Even though I bought my bike in NV it looks to be a CA model. This actually turned out to be a good thing, I ripped the CA system off and used it's cables/T joints/etc. to set up the appropriate connections for the carb syncing.

2. Removing the airbox is an infinitely destructive process. Holy cow, I don't know how you'd ever get into this thing for maintenance if you weren't removing it.

3. I ended up (and don't ask me how) 'warping' my toolkit's JIS screwdriver enough that it would 'slip' inside it's handle which resulted in me stripping 3 screws before I figured out what was going on. This resulted in a few things: First, I attached the driver to my power drill to use it. This was pretty handy. Second, I'm ordering a set of JIS screwdrivers for long term. Third, "bolts > screws"; I replaced a lot of screws with bolts (the jet kit from AreaP came with a bunch for my carbs). Fourth, I found an incredible way to remove a stripped screw. Use a jeweler's saw (like this one: http://www.amazon.com/Xacto-X75300-P...dp/B00004Z2U4/) to cut a 'flat head' on the screw, use a flat head and some heavy, but slow pressure and you can twist her off. This worked better than every other technique I found online and tried.

4. This is a retrospective one: Take photos of things as you take them apart. While Momaru's been super helpful, knowing for sure the bolt you're putting somewhere belongs there is handy. I also used some techniques where I could like rebolting to the frame after removing whatever it was holding down.

5. Hold yourself up with your core while you work on the bike. Ow my back.

I'll also be ordering a few screws/bolts that somehow got misplaced, despite my best efforts to put them in my tupperware. Doh >.<

[Yakaru]

Okay, time for the bad news update. So it looks like she's running way way way too lean; Jiggles was right. The engine gave out going up a hill back from the hardware store to my apartment and even going down the other side of the hill @ 30 MPH wasn't enough for her to push start into second (she'd spin up then die again). So I had to push her uphill about 1/2 a mile (back to the entrance to my complex). I even dropped her at one point from exhaustion -- thankfully she landed on the sidewalk so the only bruises were to things already bruised by the previous accident; namely my mirror, handlebar, and ego (my Area P was miraculously nestled between the road and sidewalk curb).

I'm taking a break to rest and rehydrate, then pushing her the rest of the way into the garage to make her get some more gas (also hooking my jumper cables up to the battery to charge her from my cage).

5'2"/100 lb girls are not meant to do that kind of pushing >.<

[Jiggles]

Yeesh! Slap those 108s in asap! Running too lean can damage your engine though idk how long it takes for that too happen

[krolinked]

I had a similiar thing happen to me. It died after riding for a while because i messed with the CA Emissions Equipment and the gas tank was not venting.

Solved it by leaving my gas cap open.

[Yakaru]

After some more investigation it may not be running lean that caused the issue; it may also be a non-vacuumed vacuum in the gas lines (the carbs had DROPS in them when I drained them); we've got a few suspicions. Sadly at this point I've lost a screw and a clamp by trying to work while exhausted in the dark; I've put the bike away and will hopefully look again just after dawn. Regardless, we swapped to 108s and lowered the needles by one 'slot', along with one more 180 on the pilots.

[Jiggles]

The middle of the three nipple hole things on the tank should be open, do you have it capped?

[Yakaru]

You mean the three with the brown tube (fuel overflow, IIRC) and the red/blue (CA Emissions)? I've capped the red/blue and the brown is connected to 'nothing'.

[Jiggles]

Originally Posted by Yakaru

You mean the three with the brown tube (fuel overflow, IIRC) and the red/blue (CA Emissions)? I've capped the red/blue and the brown is connected to 'nothing'.

There's your problem, middle one should not be capped, you can leave it open for now but you should eventually add a little air filter to it.

[Yakaru]

Ooh, that's interesting news. Do you have any suggestions re: filter?

[Jiggles]

On my last 250 I stuffed some paper towel in a rubber hose . My current one is still open but you can just get a small air filter from like oreilley or something

[Yakaru]

Okay, she's purring like a baby again (well purring and brapbrapping as menikmati put it). Here's what I did last night after pushing her back home:
Moved needle's clips one setting down (from '3rd from top' to '3rd from bottom').
Main jets swapped from 104s to 108s
Took pilot screw out 180 degrees (total of 900, 2 full turns originally and a half turn this time)
Hooked jumpers up from my car (off) to my battery (disconnected from the bike) for ~3 hours to charge
Lost a screw in the bowels of the bike, had to remove the front sprocket cover to find it. Discovered I could adjust my shifter. ( http://www.youtube.com/watch?v=hYjpE1I7XbE ). Adjusted my shifter.
Checked the fuel line filter (the line from the tank to the carb has a small filter tip in it), it was clear. Lost one of the clips that this connects to and have given up on finding it (ziptied instead)
Put a paper towel corner, folded over once, on the 'middle' (blue) gas can port, attached with a ziptie. Will replace this with a 'real' filter later. Jiggles: do you know what the diameter of that line is? I assume 3/16ths? Figuring I'll put on a small hose and a filter on the other side of the hose. Also, just curious why this is needed -- the 49 states bikes only have the overflow tube right?
Adjusted idle screw to stabilize idle at around 1500.

Tonight I'll try to do the carb sync.

[Jiggles]

You can re use the emissions lines that you pulled off