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Old January 10th, 2019, 05:31 PM   #1
Skrrrt
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Talking Hello !!! here's my 250 ^_^

Hey everybody! its nice to be part of the group finally !

so here is my ninja 250 long story short i wanted to make it into a street fighter, so I got the kit off of blk labs just the rear .. sent in wrong part made PayPal step in before me so I lost my money and got worthless parts.

so I ended up making my own naked bike ...

I hit a skunk last season and oil was leaking without me knowing I notice loss of power and a small knocking/ticking noise.. and then it slowly got louder and killed my bike... somehow I got it started and rolled home slowly... looking on some advice on what I might've damaged in the motor before I take it out and spend my time with it or should I just do a ex500 swap?

fork seals are leaking but I am doing a 636 front end swap as well.

thank you for chiming in !
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Old January 10th, 2019, 05:49 PM   #2
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Old January 10th, 2019, 09:37 PM   #3
Skrrrt
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Hey!!! glad to be a part of the group !
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Old January 10th, 2019, 10:25 PM   #4
DannoXYZ
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Hi and welcome!!!

Swapping in EX500 engine is easy if you can cut metal and weld. Rest is simple. Transmission is geared low due to it being orignally from 454LTD. Plan on installing 41t rear sprocket and 16t up front.
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Old January 10th, 2019, 10:32 PM   #5
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Old January 11th, 2019, 07:31 AM   #6
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Old January 11th, 2019, 11:29 AM   #7
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Old January 11th, 2019, 12:38 PM   #8
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Old January 12th, 2019, 10:29 AM   #9
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Old January 13th, 2019, 10:32 PM   #10
Skrrrt
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Hey Everybody !!!!

Will be starting the swap thread here next week or so depending on the freight shipment.
List of what I ordered for now.
2005 ex500 engine 100% guaranteed running cleaned and checked.
Ex500 Headers
05 harness
05 engine frame support rail(s)
ex500 Carburetor
Ignition coils
Stator
Starter
Radiator
Rectifier

I will be doing a lot of highway and twisties at highway speeds, so if someone can chime in on what chain and sprocket to use would be much appreciated and what else do you think I will need for the swap>? is my list good ? (:
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Old January 14th, 2019, 12:33 AM   #11
DannoXYZ
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You actually don't need support rails. Original engine is stressed-member, so just make some custom mounts to hang front of engine. Otherwise you'll need two custom mounts per side to attach EX500 lower rails. And you won't even come close to fitting fairings back on with those in place.

You'll also need 500 instrument cluster if you want tach, different ignition-timing. As well as 500 ignition-box. Thermostat assembly and hoses. Better to move that to side like on 250. Will need to make some brackets top & bottom to attach 500 radiator.

Search on here for 500 swaps, there's some with really good photos. If you have mini-lathe, plasma-cutter and TIG torche, that'll make things A LOT easier.

Sprockets should be 16/42t (some chains with tall plates won't fit under sprocket cover). I'm using new-gen rear-suspension on my pre-gen with ex500 rear-wheel & sprocket for 17" conversion (mine came with 41t). EX500 engine weighs 26-lbs more than 250, so plan on re-calibrating suspension accordingly, it's definitely noticeable. Also upgrade your brake-pads to Galfer to deal with extra weight and speed. Factory OEM pads have very non-linear grip & feel. Initial bite is too sensitive and when you squeeze harder, "oh ****! Where's my brakes!?!@#$!?.
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Old January 14th, 2019, 04:21 AM   #12
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Old January 14th, 2019, 06:08 AM   #13
Skrrrt
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Quote:
Originally Posted by DannoXYZ View Post
You actually don't need support rails. Original engine is stressed-member, so just make some custom mounts to hang front of engine. Otherwise you'll need two custom mounts per side to attach EX500 lower rails. And you won't even come close to fitting fairings back on with those in place.

You'll also need 500 instrument cluster if you want tach, different ignition-timing. As well as 500 ignition-box. Thermostat assembly and hoses. Better to move that to side like on 250. Will need to make some brackets top & bottom to attach 500 radiator.

Search on here for 500 swaps, there's some with really good photos. If you have mini-lathe, plasma-cutter and TIG torche, that'll make things A LOT easier.

Sprockets should be 16/42t (some chains with tall plates won't fit under sprocket cover). I'm using new-gen rear-suspension on my pre-gen with ex500 rear-wheel & sprocket for 17" conversion (mine came with 41t). EX500 engine weighs 26-lbs more than 250, so plan on re-calibrating suspension accordingly, it's definitely noticeable. Also upgrade your brake-pads to Galfer to deal with extra weight and speed. Factory OEM pads have very non-linear grip & feel. Initial bite is too sensitive and when you squeeze harder, "oh ****! Where's my brakes!?!@#$!?.

I opted out for the cluster/tach I use my phone mount as a speedo.
I will return the engine rails just thought I could make it work using the stock engine mounts, but I can custom weld something on no problem, as for fairings... there will be done as you can see on the bike ! it is Naked (:
got a welder but not a plasma cutter ): definitely would make my life easier but for now a angle grinder gotta do lol.
just made an order for the (CDI)"ignition box"
silicone hoses and thermostat came with the new radiator!
will be looking into sprockets and make the order once I'm off work, you are totally right on the brakes, first thing I did when ride is practice my braking and body that POS needs some work I catch myself dragging the rear wheel until a stop LOL"can't lie its fun"
as for the rear shock I'm letting race tech install a gs-3 shock on there and adjust it for my weight, and height.

so for my list is checking out and my swap is ready !(: thank you guys !!
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Old January 15th, 2019, 05:31 PM   #14
Skrrrt
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500 cc Swap

Day 1 of the Swap
everything drained, disconnected and loosened and hanging on by a thread.
Time for dinner
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Old January 15th, 2019, 09:56 PM   #15
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Old January 17th, 2019, 06:53 AM   #16
Skrrrt
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https://ibb.co/HG1J1j0https://ibb.co/PTzx0mk

Day 2 engine swap.
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Old January 17th, 2019, 09:29 PM   #17
Skrrrt
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Cool day 2

waiting for the 500cc!
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Old January 24th, 2019, 08:14 AM   #18
taz
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welcome and we do have a build thread page
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Old January 24th, 2019, 04:33 PM   #19
Skrrrt
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Quote:
Originally Posted by taz View Post
welcome and we do have a build thread page
That is why i stopped. and documenting a build thread. thank you.
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Old January 24th, 2019, 11:11 PM   #20
DannoXYZ
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Hey, did you chop off rear-end of frame? How much does the section you removed weigh?
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Old January 25th, 2019, 04:39 AM   #21
Skrrrt
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Quote:
Originally Posted by DannoXYZ View Post
Hey, did you chop off rear-end of frame? How much does the section you removed weigh?
rear seat, frame. taillight and rear fender added to almost 20 pounds lighter, and thats just the rear,

weight reductions
- un needed cables 1 pound
- headlight gauges and front fairing 7 pounds
-horn, tool kit/tray 2 pounds
-removed stock airbox 3 pounds
- exhaust 8 pounds new muffler only weighs 2 pounds.
-side lower and upper fairings - 8 pounds

pretty much made up for the extra weight the 500 will take.
easier wheelies
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Old January 26th, 2019, 06:34 PM   #22
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