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Old March 29th, 2016, 07:16 AM   #1
SpotTheDogg
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2000 ZZR250-GP Race bike

Hello folks, I do not currently own a Ninja250 but I am heavily involved in building a ZZR with my friend Paul, we have dubbed it -GP because we used bodywork from TYGA designed to fit a Suzuki RGV250

Paul is a British ex-pat who lives in Cape Breton, he raced in England before moving to Canada. He raced with me the past two seasons on a 2008 Ninja250, that's him behind me in 2015 (he's not often behind me)



Anyway he wanted a project this winter and we have been talking about ZZR250's a fair bit (mostly because of the aluminum frame and higher power rating) so he decided to sell the Ninja to another friend and look for a good candidate. In late November I found it, a 2000 with only 12,000Kms on the clock. This one was a little road rashed and the price was right at $1350 I went and got it for him as he is another six hours drive from me and eight from the bike. Once it was in my yard I had it stripped within two days preparing to sell all unwanted street parts. The only real mod I did while I had it in the driveway was to cut about five pounds off the front fender


Paul is a good fabricator and has some helpful tools in his shop.

Enough chatting, here's some pics

The front wheel is a 17x3.0" from a GS500 since the stock wheel is a 17x2.15", this was as easy as turning two axle spacers.


I had these rearsets that didn't fit anything so he made some adapter plates



Custom race subframe



Undertail



Beginnings of the subframe with the Akrapovic knockoff mufflers, the headers are stock and the up-pipes are made from an old dinged up 4-1 header



Now the bodywork is finally all mounted, the last piece will be to mold a carbon fiber tank guard to cover the indent for the stock banana seat.







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Old March 29th, 2016, 07:20 AM   #2
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Old March 29th, 2016, 07:59 AM   #3
SpotTheDogg
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I will now give a little history, this is the bike after I had it a day



This is the fender-ectomy result



This is the deeper 'sump' from a new gen Ninja250, supposed to help.



Paul was able to make an upper fairing mount that now holds the Ballistic 4 cell 1lb battery, the RR and the ignition unit! The starter relay now hangs on a custom bracket from the right coil pack bolt. The rear shock is GSX-R600 with custom dogbones raising the rear 20mm.



The front master cylinder is a 14mm unit from a 2004 ZX6RR, they were too small for that bike and we hope it's not too big for this single caliper bike!

This is my GF's old EX250 I did a lot of work to



I almost forgot about this one, my old EX500 that also saw a lot of work.



My street bikes



my race bike



Me and Paul at the track, oops I forgot to mention our track! Atlantic Motorsports Park, Shubenacadie, Nova Scotia.





My girlfriend/partner racing her CBR250R

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Old March 29th, 2016, 08:20 AM   #4
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I read up on how replacing the ex250f oil screen housing with the ninja 250r oil drain housing will prevent the hard cornering/braking oil starvation, and I always planned to do it, but I never ordered the part. This is something I will definitely do before I go project 265.

Cool project btw.
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Old March 29th, 2016, 09:39 AM   #5
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Sweet, I love my ZZR, just gave it a good tidy up with soem upgrades over the winter.
It now sports a KR1-S front & rear end, with Nissin 4-pot calipers, & a VTR250 rear wheel for a close match to the KR1-S 5 spoke front ! Next will be a 282cc big bore.

What;s the issue with the sump oil supply ? I've not come across that before !
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Old March 29th, 2016, 09:45 AM   #6
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Sweet, I love my ZZR, just gave it a good tidy up with soem upgrades over the winter.
It now sports a KR1-S front & rear end, with Nissin 4-pot calipers, & a VTR250 rear wheel for a close match to the KR1-S 5 spoke front ! Next will be a 282cc big bore.

What;s the issue with the sump oil supply ? I've not come across that before !
It's not an issue.

However, the new gen sump is larger and allows more oil to be carried. Keeps oil temps a bit cooler and provides a safety margin of sorts in regards to capacity. It also makes oil changes a bit easier.
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Old March 29th, 2016, 09:55 AM   #7
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It's not an issue.

However, the new gen sump is larger and allows more oil to be carried. Keeps oil temps a bit cooler and provides a safety margin of sorts in regards to capacity. It also makes oil changes a bit easier.
I couldn't find the link to replacing it, but Its as simple as buying the newgen cover off ebay, and a newgen gasket online, then bolting it up correct? No machining or special gaskets or anything.
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Old March 29th, 2016, 01:53 PM   #8
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Yes, direct bolt on. It is supposed to help keep oil on the crank under repeated hard braking like found on some race tracks. I bought one with the gasket and bolts for $30 on eBay
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Old March 30th, 2016, 05:06 AM   #9
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Yes, direct bolt on. It is supposed to help keep oil on the crank under repeated hard braking like found on some race tracks. I bought one with the gasket and bolts for $30 on eBay
Got mine for $18 and shipping on eBay from Ann Arbor, Mi! Now to install it...
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Old April 23rd, 2016, 08:47 PM   #10
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For those interested here is how Paul's ZZR looks today, Octo Pramac Ducti inspired









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Old April 24th, 2016, 05:56 AM   #11
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nice, Scott! How much does it weigh? I have been disappointed by MotoSeries not having any track time this year, at least so far... they are repaving/rennovating the track at Nelson Ledges, new owners and won't be ready until next year. and I have some health problems that will limit my participation for the next month or more, but hope to be at Mid-Ohio to race Vintage Days!
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Old April 24th, 2016, 07:46 AM   #12
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That looks AMAZING!!!
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Old April 24th, 2016, 08:52 AM   #13
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Looks great!
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Old April 24th, 2016, 05:53 PM   #14
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Quote:
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nice, Scott! How much does it weigh? I have been disappointed by MotoSeries not having any track time this year, at least so far... they are repaving/rennovating the track at Nelson Ledges, new owners and won't be ready until next year. and I have some health problems that will limit my participation for the next month or more, but hope to be at Mid-Ohio to race Vintage Days!
Sorry to hear that Charlie, we are three weeks from test and tune then another week to round one.
Paul is trying to find two scales to get the weight, I'd guess 290lbs
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Old April 25th, 2016, 08:22 AM   #15
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Old April 25th, 2016, 08:33 AM   #16
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Very nicely done!!!! Your attention to detail is good.

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Old April 29th, 2016, 03:11 PM   #17
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Great work!
This is almost exactly what we are trying to accomplish. We sourced a Tyga 2 into 1 replica header of ebay for $216.....chinese clipons and rearsets as well.
For now we are gonna chop off any extraneous steel from the subframe leaving only enough to support the rider. Suprisingly, the stock fairing stay is pretty light so we will use it for now till we can make something out of aluminum.
We were torn on fairings but yours has gotten us interested in those fairings too. We are trying to fit a TZ 250 tail on it next week.
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Old May 21st, 2016, 04:02 AM   #18
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Old May 29th, 2016, 01:51 AM   #19
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Hello SpotThedogg.
I'm haciedo something like your bike, but I will use it on the street.
I have a front wheel ZX400G installed to keep the speedo and to mount a 110/70/17 tire.
You have not thought about changing the rear wheel by a 4x17 inch?
The tire 140/70, is deformed in a 3.5 inch rim.
I thought about installing the rear wheel ZXR400H (4.5 inches) and a tire 150/60/17, with the support chain of a ZXR400L, installing a rear sprocket 42 teeth
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Old November 22nd, 2016, 02:32 PM   #20
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Quote:
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Hello SpotThedogg.
I'm haciedo something like your bike, but I will use it on the street.
I have a front wheel ZX400G installed to keep the speedo and to mount a 110/70/17 tire.
You have not thought about changing the rear wheel by a 4x17 inch?
The tire 140/70, is deformed in a 3.5 inch rim.
I thought about installing the rear wheel ZXR400H (4.5 inches) and a tire 150/60/17, with the support chain of a ZXR400L, installing a rear sprocket 42 teeth
4" would be nice but no desire to go 4.5" or 150, the 140's are nice
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Old November 22nd, 2016, 02:38 PM   #21
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Old November 22nd, 2016, 02:44 PM   #22
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I figured since I haven't been around I should update with some action shots from this season!











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Old November 22nd, 2016, 03:10 PM   #23
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Old November 22nd, 2016, 03:15 PM   #24
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Looking good.
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Old November 22nd, 2016, 06:00 PM   #25
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Old November 22nd, 2016, 08:38 PM   #26
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Very nice & I love the Pramac theme!
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Old November 23rd, 2016, 08:28 AM   #27
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Old December 5th, 2016, 01:36 PM   #28
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Nice execution. Im planning a similar build, have the ZZR frame and swinger in the shop working on some misc. things; bearings, weight reduction, etc.

The biggest thing I noticed is the swingarm with its adjusting hardware seems to weigh just as much as the frame - there are gains to be had there certainly. Did you ever confirm your 290lb estimate?
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Old December 5th, 2016, 03:23 PM   #29
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Have a look at a KR1-S swingarm, its the same weight as the steel oem, but much bigger section. See pic's here.

KR1-S Picture
https://upload.wikimedia.org/wikiped...saki_KR1-S.jpg

My ZZR250
https://www.dropbox.com/sh/kcg0auipy...fWBY3anya?dl=0

Loving it, just passed annual inspection today YEAH.
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Old December 6th, 2016, 04:31 PM   #30
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Seeing as though these bikes aren't in the U.S. market I don't know much about them. Do they use the same engine as our EX250? Are there many "parts bikes" on the market in Canada or Europe? I'm thinking maybe someone could send me a frame, triple and swing arm?
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Old December 7th, 2016, 07:51 AM   #31
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Seeing as though these bikes aren't in the U.S. market I don't know much about them. Do they use the same engine as our EX250? Are there many "parts bikes" on the market in Canada or Europe? I'm thinking maybe someone could send me a frame, triple and swing arm?
I purchased mine on eBay.ca, but it actually shipped from upstate NY. I can confirm the lower engine mount fits the newgen engine. If someone has a spare newgen upper engine mount I will pay shipping to test - I had planned on making a custom aluminum one.
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Old May 24th, 2017, 06:47 PM   #32
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Tasteful but RAD at the same time. Love that thing
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Old January 3rd, 2019, 08:01 AM   #33
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I haven't checked in in a long time, thanks for the kind words.

We have started working on another project, partly inspired by posts I saw here.

We bought another ZZ-R 250 for the frame and stuffed a fresh Ninja500R race engine in it It will be running a Ninja600R aluminum swingarm, a FOX Twin Clicker shock, 2004 ZX-6R forks and a lot of the goodies we developed for the above bike. Wheels will be SV650 rear and GS500 front. We found a nice old Muzzy race pipe for it as well!

I am going to start a build thread in the racers section.

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Old January 3rd, 2019, 08:09 AM   #34
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A few iterations of the ZZR250GP since I last checked in, Paul build a Honda NSF250R Moto3 inspired under tail exhaust.







We had the ZX-6R front end on it for a while, but Paul said it was incredibly harsh. he abandoned it for the stock fork and we didn't look at it again. Only this weekend did he tell me it had come from a stunter's bike, doh! The compression circuit was probably modified. I had just done a refresh and springs, couldn't understand why it was un-rideable.

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Old January 3rd, 2019, 08:28 AM   #35
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Looking good. I'd be interested in some shots of the engine in the frame, so will look for your build thread. I've thought about this a few times, as GPZ500's are really cheap here, just wasn't sure if the engine would fit in the frame.

So I went with the big bore kit, which I made 2 years ago & still have not had time to fit. I'm hoping to do it this winter but New Year has arrived & I haven't done anything to my bikes yet

Keep up the good work
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Old January 3rd, 2019, 08:34 AM   #36
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Looking good. I'd be interested in some shots of the engine in the frame, so will look for your build thread. I've thought about this a few times, as GPZ500's are really cheap here, just wasn't sure if the engine would fit in the frame.

So I went with the big bore kit, which I made 2 years ago & still have not had time to fit. I'm hoping to do it this winter but New Year has arrived & I haven't done anything to my bikes yet

Keep up the good work
I did post a new thread with good engine mount pics, you will see it is not for the moderately skilled home mechanic.
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Old January 3rd, 2019, 09:05 AM   #37
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LOVE THIS THREAD

and pretty sure I will feel the same about the other lol
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Old January 3rd, 2019, 09:12 AM   #38
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LOVE THIS THREAD

and pretty sure I will feel the same about the other lol
Thanks!
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Old January 4th, 2019, 12:40 AM   #39
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Amazing work! Happen to have any wet-weights for these bikes?
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Old January 4th, 2019, 06:01 AM   #40
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The 250 is at 300lbs, not full tank, unsure of just how much fuel was in it when he weighed it. We expect the 500 to be 340lbs.
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