2011 SE going to pieces

[sleepless]

On purpose

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Just picked up this 2011 a week ago and its already in pieces in my garage. It had 900 miles when I bought it and I got a solid deal. Only problem is, the owner decided all those factory recommendations were bullshit and NEVER CHANGED THE OIL..

Hopefully, the damage isn't too severe. I've got a new filter and some 20W-50 oil (preparing for that Texas heat) that I'll put in before it goes a another mile.

Spent entirely too much ordering mods already just to get it to where I like it. My room:
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Hooked up the new LED turn signals, installed a new flasher relay and a couple of diodes, and rewired the integrated taillight that was already there. (Had to remove the old bulb that the previous owner had simply wrapped in wax paper and electrical tape and left in-line ) Also redid the diy fender elimination to remove the plate light. Still need to pickup some LED bolts..

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Also finished the shogun crash kit install. I had to pick up a torque wrench and some larger hex key socket wrench bits to finish the install, but that just means my tool kit is bigger!

There seem to be a half dozen different kawi ninja forums, but the wiki here and some of the diy tutorials really helped on all the installs. I appreciate all the hard work people have already done to make my life easier, so I figured I should join and show the results! You guys rock

[cuz]

Welcome to the 250 party.



FYI u spelled Houston wrong idk if you did it on purpose

[Snake]

Hello and welcome.

[sleepless]

Thanks guys. Changed the oil yesterday - it was black! With a few shiny bits of metal flakes at the bottom.

Not what I wanted to see, but I expected it. At least it's got fresh dino oil in it now!

[EthioKnight]

Welcome aboard! Kudos to you for doing all that needs to be done yourself. As long as you have the bike stripped, check your coolant levels and flush and refill as needed. If you're not itching to hit the road, I'd also recommend shimming your needles for a much better performance (just one more step - remove gas tank ).Good luck and happy trails.

[KJohnson21]

[sleepless]

Extended wires, added oem connectors, and have since added a bead of black silicon sealant to protect the fairing paint.

2012-06-10_14-30-05_473.jpg

per Momaru's great diy: http://www.ninjette.org/forums/showthread.php?t=36477

[sleepless]

Picked up on Amazon, for ~$18: http://www.amazon.com/Bright-Black-L...cmu_pg__header

Out of the box:
Copy of 2012-06-09_18-37-06_862.jpg

Rigged up some y-connectors with ~3 inches of 22 gauge wire and two female quick-disconnect bullet connectors on each:
2012-06-10_15-27-44_723.jpg

Installed into license plate. This required slightly enlarging the holes in the license plate AND the bracket:
2012-06-10_15-52-52_226.jpg

Pulled the wires up through a hole in the tail (for extra protection against the elements):
2012-06-10_16-03-13_889.jpg

LEDs connected to Y-splitters and Y-splitters permanently soldered to original plate light wires: (The blue taps are for my always-on red LED strips under the tail)
2012-06-10_16-26-29_719.jpg

Done!
Copy of 2012-06-10_16-28-53_769.jpg

This way, the quick disconnect bullet connectors allow me to take the license plate off without cutting anything if I ever need to.

[sleepless]

The previous owner dropped my baby
2012-05-19_16-51-45_65.jpg

Time to do some work!
I used this DIY as a guide: http://faq.ninja250.org/wiki/Plastic...ith_ABS_cement


Tools required:
ABS Cement (http://www.amazon.com/gp/product/B00...ls_o06_s00_i00)
Spare ABS Plastic - 12" X 12" X 1/8" (http://www.amazon.com/gp/product/B00...ls_o01_s00_i00)
Soldering iron (and hopefully extra tips, as this one will be useless afterwards)
Dremel (not shown)

2012-06-10_17-38-02_782.jpg

Dremel/sand the paint out of the cracked area. I had to chop a good bit off as it was warped outwards. Create a shallow V to later fill in with ABS cement:
2012-06-10_17-45-18_851.jpg

Backside can be much rougher where no one will see:
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Cut spare ABS to shape of chunk missing:
2012-06-10_18-24-41_337.jpg

Weld the cracks closed and the spare ABS to the fairing with the soldering iron, being careful not to get things too hot:
"Run the hot iron down the length ... with your finger on the [other] side, moving gingerly up and down the surface. The idea is to keep the feeler fingertip from getting too hot... If your finger can't take the heat, neither can the paint."

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Backside:
2012-06-10_19-02-25_991.jpg

Here, I did some minimal sanding to reduce the surface roughness. Then use the ABS cement in a well-ventilated area to finishing healing the wound.
2012-06-10_19-02-41_985.jpg

In the future - painting! Maybe..

[sleepless]

Safety mods FTW!

37 Mode Flasher sourced for the bargain price of $20 here: http://www.3rdbrakeflasher.com/index...baee5c39c0c6f5

I had prepared myself to weatherproof the circuit board somehow, but was pleasantly surprised to discover it was already 100% covered! I'm very impressed with the tight tolerances on whatever coating they used - they even covered the connections to the wires. Nice.
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This is the OEM connector for the taillight we plug into (Taillight side to the right, battery power side to the left):
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Attached some OEM connectors, following the included wiring diagram (*This is the correct wiring configuration. Red = power in, Yellow = power out, Green = through-wire for running lights, Black = ground):
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Check the internal LED to make sure the power and ground are hooked up:
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Installed! I also bundled and wrapped the white 'change-mode' wires in electrical tape after settling on my desired flasher pattern. The tail is becoming very full with wiring and connectors. Still neatly organized, more or less..
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*IMPORTANT
The RED wire is NOT the power wire for the taillight. The BLUE/BLACK wire IS. The red wire is for the "running lights" in the taillight that are dimly light at all times. I had this wrong when I first hooked it up. Luckily, with the aid of a small eyeglasses screwdriver, it is easy to reorder the tines in the connectors. It is not as easy if you decide to hardwire

[sleepless]

I'm throwing all the mods I've been doing into this thread. Most of these have been covered on the forums, but if anyone finds these useful and wants further explanation/pictures, just ask.

[sleepless]

Rear turn signals installed in stock locations:
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Plug and play!


Rear LED turns + Integrated taillight + LED Plate lights + Proton connection test:
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LEDs FOR EVERYONE!

[sleepless]

Picked up a pair of integrated mirrors from the2wheels for ~$40: http://shop.the2wheels.com/Integrate...-085B-pair.htm

Upon arrival from Hong Kong. Actually pretty quick shipping, considering the distance:
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This diy was a nice resource: http://www.ninjette.org/forums/showthread.php?t=77788

Remove your front fairing and headlight assembly to access the mirrors. Headless
2012-05-22_23-54-23_263.jpg

The hexnut you need to loosen to remove the stock mirror from its base is hidden under a felt pad:
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Integrated mirror assembly:
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Stock mirror assembly:
2012-05-22_23-38-19_779.jpg

If you notice, the base and rubber boot that comes with the "universal" integrated mirror is huge and unsightly. It extends way beyond the bolt holes. No way I'm installing that beast on my sleek machine!

Additionally, the stock base feels like a hardened steel alloy vs the plastic integrated mirror base.

In order to reuse the stock base and not have to fit the "universal" base, we'll need to remove both bases from their mirrors and slim down the integrated mirror attachment point.

The stock mirror attachment point is skinnier than the integrated attachment point:
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I used the dremel w/ sanding attachment to slowly shave off layers of plastic, checking regularly for fit:
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Reusing the stock hardware - two washers, lock washer, nut, and bolt - test fit the integrated mirrors to the bike:
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From the front (not necessarily angled correctly):
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TO BE CONTINUED...

Still have to reinstall the front fairing / headlights and find a way to route the power wire. I really don't want to put more holes in the fairings, so I'm considering just routing it underneath the wind shield and down. Hmmm..

[Countersteer]

Hey, Sleepless! Looks like you're well on your way making that thing your own! I was looking through your posts and thought you might be able to help me out. I'm looking for a newgen mirror to attempt an integrated turn signal self install and am hoping to find an unwanted donor to experiment on. Here is the thread I created just the other day trying to find one;
http://www.ninjette.org/forums/showthread.php?t=106238

Anyway, if you think you could help me out let me know. I really just need the mirror part to determine how to integrate a turn signal into it.

Thanks!

[sleepless]

Originally Posted by Countersteer

Hey, Sleepless! Looks like you're well on your way making that thing your own! I was looking through your posts and thought you might be able to help me out. I'm looking for a newgen mirror to attempt an integrated turn signal self install and am hoping to find an unwanted donor to experiment on. Here is the thread I created just the other day trying to find one;
http://www.ninjette.org/forums/showthread.php?t=106238

Replied

[sleepless]

TO BE CONTINUED...

Reattached to headlight fairing:
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Extended the cable and added OEM male connector:
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[sleepless]

Picked up the (500 page) Kawasaki Service Manual today for $6, wOOT!

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[Renner]

Were did you find it for $6??

[sleepless]

printer at work + FedexKinkos binding!

[sleepless]

Upgraded the Shoei with 3M Scotchlite Reflective Tape:

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[tsdexter]

Originally Posted by sleepless

Upgraded the Shoei with 3M Scotchlite Reflective Tape:

Attachment 19426

Attachment 19427

Attachment 19428

That's awesome dude, love the squared off skull and cross bones on the back

[sousuke86]

Do you have red LEDs behind the license plate too? thats a lot of red light onto the wheel. awesome

[sleepless]

Originally Posted by sousuke86

Do you have red LEDs behind the license plate too? thats a lot of red light onto the wheel. awesome

Yep. Two strips of red LEDs under the tail. I've been thinking about turning them into 3 strips - two to blink as turn signals and one always-on... but I already have 4 sets of turn signals so that may be a bit overkill

[Stingray1000]

Welcome!