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Old May 24th, 2015, 01:08 AM   #201
Mojavemesa
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I know this is not the category for pregen or 500 info but this thread has the most info for a 500 swap on all the interwebs, so please excuse me posting here.

The bike was insane with the 250 sprockets but was at 7krpm at 70mph... with the 500 sprockets on it its still fun but I think I'll be ordering a 15tooth front sprocket for it.

The rear suspension was a no go. I don't have the setup for my lathe to cut the bearing seat deeper in the swingarm to then be able to narrow the pivot. I sat all the other suspension parts side by side and everything out of the 500 would lower my bike and I don't want that. I think if I'm going to do a swingarm swap the work would be worth it if it were lighter. I installed air preload fittings in my forks and refilled with 15 weight and adjusted oil volume to hydrolock near bottoming.

Crazy, you're way ahead of me. I was already looking at the zx600d for its wheels but it's good to see what you did with the suspension bits.
And thank you for the info, Bill.
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Old May 26th, 2015, 05:10 AM   #202
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Quote:
Originally Posted by Mojavemesa View Post
I know this is not the category for pregen or 500 info but this thread has the most info for a 500 swap on all the interwebs, so please excuse me posting here.

The bike was insane with the 250 sprockets but was at 7krpm at 70mph... with the 500 sprockets on it its still fun but I think I'll be ordering a 15tooth front sprocket for it.

The rear suspension was a no go. I don't have the setup for my lathe to cut the bearing seat deeper in the swingarm to then be able to narrow the pivot. I sat all the other suspension parts side by side and everything out of the 500 would lower my bike and I don't want that. I think if I'm going to do a swingarm swap the work would be worth it if it were lighter. I installed air preload fittings in my forks and refilled with 15 weight and adjusted oil volume to hydrolock near bottoming.

Crazy, you're way ahead of me. I was already looking at the zx600d for its wheels but it's good to see what you did with the suspension bits.
And thank you for the info, Bill.
Cool to see someone else tackling this, on our side of the pond. I am also slowly compiling parts and money to tackle this project. I was ready to tear it apart over the winter but the weather was far too cold to spend in the garage (even with a decent heater).

Good luck!
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Old May 26th, 2015, 09:14 AM   #203
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I am wondering why you guys are so eager to put this much effort into building a bike that Kawasaki already produces. Not trying to be a dick, just wondering.
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Old May 26th, 2015, 09:16 AM   #204
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I am wondering why you guys are so eager to put this much effort into building a bike that Kawasaki already produces. Not trying to be a dick, just wondering.
It's a hobby dude. But for me I prefer the looks of the 250 and also like
the tank layout for cafe racer look.
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Old May 26th, 2015, 09:20 AM   #205
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It's a hobby dude. But for me I prefer the looks of the 250 and also like
the tank layout for cafe racer look.
I guess I cant't say I haven't put a lot of time and money into something for "the love of the sport."
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Old May 26th, 2015, 10:47 AM   #206
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I am wondering why you guys are so eager to put this much effort into building a bike that Kawasaki already produces used to produce. Not trying to be a dick, just wondering.
FTFY. I know there are some nearly new (maybe even brand new) ones still out there, but at this point they've been out of production for 6 years.

One of these days I'll actually ride a 250, but my understanding is that the 500 and 250 are pretty similar, even more so when the 250 has a 500 engine in it. It's probably not worth doing this swap unless you've got a great 250 that needs an engine and find a deal on a 500 or something. Most people who want a 500 would be better off just buying a 500 (around here they about the same price as 250, or even cheaper). But if you enjoy this kind of work and have the bikes available to you, by all means, do your thing.

I wouldn't mind having the updated styling of the NewGen or 300 with my 500's engine in it (preferably with FI too). I'm not sure if it would be easier to get other fairings to fit the 500 or just stuff the 500's engine into the Ninjette...
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Old May 28th, 2015, 02:14 PM   #207
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It was the money for me. 400 got me a 500 with a lot of back registration owed. Plus there Is a built not bought cool factor and once I finish squeezing the lower fairing on it'll be fun to mess with people on the mountain roads
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Old May 29th, 2015, 02:05 PM   #208
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Agree with previous posts on looks of 250 and power of 500. I have not done this swap but have toyed with it in my mind...what are the considerations of the 300 FI system with 500 engine?
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Old May 29th, 2015, 02:46 PM   #209
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I'd love my 300 to have a 500cc engine --but no skills to do that (will trade PC/Network training or repair )

However w small bike market heating up... I fully expect a new ninjette w bigger CC's to be coming soon enough..maybe they'll even bring back that Ninja 400 they had up in Canada for awhile.
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Old May 30th, 2015, 07:56 AM   #210
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I'd love my 300 to have a 500cc engine --but no skills to do that (will trade PC/Network training or repair ;))
Me too. =)


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However w small bike market heating up... I fully expect a new ninjette w bigger CC's to be coming soon enough..maybe they'll even bring back that Ninja 400 they had up in Canada for awhile.
The Canadian Ninja 400 was just a 650 sleeved down to a lower displacement. That's the last thing I want, and I'm assuming many Ninjette riders would agree with me based on the comments I've seen about the 650 feeling relatively big and clumsy. I want a Ninjette with a (slightly) bigger bike's power, not a big bike with a Ninjette engine. I really do like my 500 in that regard, but it's really a design from 30 years ago with only minor updates 20 years ago.
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Old May 30th, 2015, 09:40 PM   #211
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Was hoping more for it to come back in name alone, but be a beefed up 300.
I forgot that is was sleeved down 650...so doubt they will do a complete redesign of it
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Old May 31st, 2015, 03:39 AM   #212
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If I had the money I'd swap in the 650 engine with its stock fi. I bet it'd be a smaller and lighter engine than the 500 engine is.
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Old June 1st, 2015, 08:00 AM   #213
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Me too. =)




The Canadian Ninja 400 was just a 650 sleeved down to a lower displacement. That's the last thing I want, and I'm assuming many Ninjette riders would agree with me based on the comments I've seen about the 650 feeling relatively big and clumsy.
The bike maybe, but the power unit is actually pretty compact and light. I seem to remember somwhere reading it was smaller and lighter than the 500 unit.
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Old August 23rd, 2015, 07:39 PM   #214
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I am working on the same project now and I'm wondering if you could post a picture of the thermostat
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Old August 24th, 2015, 04:25 AM   #215
Mojavemesa
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I hope this helps you. I had to weld two tabs on the frame to mount the thermostat housing and take a ball peen hammer to slightly dent the under side of the tank to clear the fill cap.
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Old August 24th, 2015, 05:48 AM   #216
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I hope this helps you. I had to weld two tabs on the frame to mount the thermostat housing and take a ball peen hammer to slightly dent the under side of the tank to clear the fill cap.
Nice! If you didn't want to / can't weld it, you can probably use clamps to provide the mount points for the thermostat.

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Old August 27th, 2015, 03:43 AM   #217
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The bike maybe, but the power unit is actually pretty compact and light. I seem to remember somwhere reading it was smaller and lighter than the 500 unit.
it is smaller and lighter BUT invisibill does have a good point...
for one it not all about compactness that matters since the bike's behavior while riding is greatly affected by the mass of the moving components (rotation of the -heavier- crank, longer rods, bigger piston etc)
but most important is the factor that the 650 (and its downsized 400 version) is basically half a ZX-12 engine with longer stroke, so intake shape and throttle bodies are straight and above the engine, so that cannot be placed on a bike with a frame that runs over the engine...
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Old August 27th, 2015, 06:05 AM   #218
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angle of the inlet ports would definitely be an issue
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Old June 12th, 2016, 05:33 AM   #219
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Yes you read it right. We have an ex500 motor installed and running in a Ninja 250. The pictures are rough I will add more and video as we tidy things up.
hi im new on here ive built the same bike 2009 250r with the ex500 engine its not that hard to do and highly recomended! all the myths about bigger engine twisting the frame is rubbish built mine about 3 years ago now and ive ridden it all over europe over this time and i ride it hard and the frame is fine!
still running stock suspension with no probems but upgraded front bake with braided hose and brembo caliper.
this year im upgrading engine to the 650r engine and looking into upgrade rear shock and front forks.
any of you guys can recomend what rear shock and forks or twin disc conversion?
thanks beau
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Old July 1st, 2016, 09:39 PM   #220
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Very cool!
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