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Old November 22nd, 2015, 07:38 PM   #1
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Race Prepping - Slow Build Thread

So i have started my budget friendly race build since it is getting cold out.. Here's how she sits now. Starting with weight reduction. Cutting all the unnecessary tabs off and starting to cut down the wire harness. Being that i am trying to save money with doing this i cut down my cluster to be just my tach, oil pressure light and neutral. Function over form. Its not pretty but it gets the job done.
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Old November 22nd, 2015, 08:02 PM   #2
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Keep in mind there are some racing classes that limit modifications! It may not be of concern for you but just making sure you're aware in case it causes you problems later!
Cheers, have fun & good luck!
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Old November 22nd, 2015, 08:21 PM   #3
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Yea i've read the rules for where ill be racing at, i think i am within the guidelines. Thanks!!
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Old November 23rd, 2015, 10:09 AM   #4
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i just read what i typed again... hope that didnt come off the wrong way, didnt mean for it to haha
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Old November 23rd, 2015, 11:00 AM   #5
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i just read what i typed again... hope that didnt come off the wrong way, didnt mean for it to haha
No; not at all!

I had a similar thought you might feel I was being a nanny and it's none of my business! I know in my case I was all set to put on decent, adjustable forks on my 250 for racing, found a perfect set and was about to buy them but luckily; I read our club rules and discovered it's not permitted!

I thought I'd pass on my "wisdom" and maybe prevent a problem for you or another reader!
We're all good!
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Old November 23rd, 2015, 11:15 AM   #6
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Thanks for looking out!!

I think im ok with what i am doing, i am a little worried about the removing the unneeded tabs but too late now haha. I know that i can not cut off the subframe behind the seat but i dont see why i wouldnt be able to remove the little tabs here or there.
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Old November 23rd, 2015, 10:16 PM   #7
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Aint nobody gunna care about tabs in 250 racing.
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Old November 24th, 2015, 11:30 AM   #8
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Thats what i was thinking.... And if a few of the unneeded wires went missing also haha
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Old November 25th, 2015, 12:39 PM   #9
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@Dsheumaker post your rules. Maybe someone has some experience in bending those particular rules an might be able to help you out with your build.
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Old November 25th, 2015, 12:41 PM   #10
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@Dsheumaker post your rules. Maybe someone has some experience in bending those particular rules an might be able to help you out with your build.
I wouldn't say it's bending the rules haha by ill post them when I get home later
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Old November 28th, 2015, 04:47 PM   #11
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Thats what i was thinking.... And if a few of the unneeded wires went missing also haha
I am in the process of doing the same thing. Interested in how you cut down the harness.
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Old November 29th, 2015, 06:10 AM   #12
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Just studied the wiring schematic for awhile, then slowly cut it open a little bit at a time so i didnt end up with a huge rats nest. I left the low beam, brake light, and front brake switch intact so i can take it out on the street if i want. Just take your time is the best advice i can give ya, oh and plan out what you are going to be removing. It took me about 5 hrs. could probably do it in a couple of hrs if i had to do it again.
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Old December 4th, 2015, 04:04 AM   #13
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Anti-slosh tank foam works really well on mine. I may help you with your bike,as i have already got my bike down to 146kg(after race) with another -2kg by next week!
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Old December 16th, 2015, 08:55 AM   #14
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Just finished up on my carbs, and just ordered a bunch of stuff. Got my 06 GSXR shock for $25 on ebay, the riser dogbones for it, block off plate, pod filters, and my slip on...

Still lots of work to do and lots of parts to be bought
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Old December 16th, 2015, 12:09 PM   #15
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Oh and Racetech springs and gold valves ordered.... ok i need to stop spending money!!!
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Old December 16th, 2015, 12:23 PM   #16
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Oh and Racetech springs and gold valves ordered.... ok i need to stop spending money!!!
we are literally doing the same build. I have my GSXR shock installed, but am waiting on some 130MM bolts. I didnt like the 120mm. they just were a little short for my liking.
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Old December 16th, 2015, 12:26 PM   #17
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I havent sourced out my hardware for the gsxr shock yet, figured i would shop for those once i get a nice list together of the parts i need. Trying to get this all knocked out sooner then i was planning on it since there is a track day in Feb i may try to do.
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Old December 16th, 2015, 12:28 PM   #18
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I havent sourced out my hardware for the gsxr shock yet, figured i would shop for those once i get a nice list together of the parts i need. Trying to get this all knocked out sooner then i was planning on it since there is a track day in Feb i may try to do.
I got my bronze spacers and bolts from my local ACE hardware, but they longest bolts they have is 120mm. it would work but the bolt wont go all the way through the nuts. So I ordered some 130mm from fastenal.
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Old December 16th, 2015, 02:55 PM   #19
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Oh and clip ons.... take away my computer access please!!!!

Things left to buy or get in order... exhaust gaskets, possibly shims for valves, spark plugs.... gonna have someone do my wheel bearings for me. but i think that's it for ordering and spending money on it... i know something will come up.

I need to make my faring stay also.
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Old December 22nd, 2015, 01:49 PM   #20
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Parts Day!

Got some stuff in the mail

Hopefully the mail gods continue to bless me with early deliveries so i can get a lot of work done this weekend.

I got the angled pod filters, havent messed with them much yet but they seem to go on easier with the angles facing away from each other. Maybe i can get them to on on straight, ill play with them tonight.
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Old December 24th, 2015, 08:28 PM   #21
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Got some stuff in the mail

Hopefully the mail gods continue to bless me with early deliveries so i can get a lot of work done this weekend.

I got the angled pod filters, havent messed with them much yet but they seem to go on easier with the angles facing away from each other. Maybe i can get them to on on straight, ill play with them tonight.

nice haul! I am doing with the single K&N filter.

today I got the HRC rear brake res kit. it just replaces the entire reservoir with a plastic tube.
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Old December 26th, 2015, 01:25 PM   #22
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nice haul! I am doing with the single K&N filter.

today I got the HRC rear brake res kit. it just replaces the entire reservoir with a plastic tube.
I just got some tubing from lowes and made my own. It was like $.75 for a foot of tubing haha
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Old December 26th, 2015, 03:08 PM   #23
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Emulator installed

So had a great Christmas, spend a lot of time with the family and relaxing. Started back on the bike today, installed my emulators. Was not as bad as i thought it was gonna be. To be honest get the cap off and figuring out the preload spacer was the hardest parts haha. Defiantly think that anyone could install them if they take their time. Since i did the emulators and springs, i wrote done all my settings for the front so i can actually keep track of how what changes i make feel on the bike.

Also got my exhaust in the mail today its so light compared to the stock one!!!
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Old December 26th, 2015, 08:46 PM   #24
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Awesome, glad to see progress! It's coming along. I'd be keeping the same pace if the 'mail gods' were equally kind.
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Old December 26th, 2015, 09:39 PM   #25
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I just got some tubing from lowes and made my own. It was like $.75 for a foot of tubing haha

How do you allow for air movement as the fluid level changes?
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Old December 27th, 2015, 08:17 AM   #26
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How do you allow for air movement as the fluid level changes?
Just capped it off like the one in the pic.
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Old December 27th, 2015, 08:53 AM   #27
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There was another thread here, a while back, where we were debating the need for venting of the reservoir (tube) as the fluid is pushed into the caliper.

The question being how that system would allow movement of the fluid level in the tube without letting air in. A regular reservoir has an expandable seal that is drawn down as the fluid level drops, but doesn't allow air into the system.

That system (sealed tubing) doesn't, so a vacuum is created inside the tube as your apply the brake.
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Old December 27th, 2015, 11:37 AM   #28
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So had a great Christmas, spend a lot of time with the family and relaxing. Started back on the bike today, installed my emulators. Was not as bad as i thought it was gonna be. To be honest get the cap off and figuring out the preload spacer was the hardest parts haha. Defiantly think that anyone could install them if they take their time. Since i did the emulators and springs, i wrote done all my settings for the front so i can actually keep track of how what changes i make feel on the bike.

Also got my exhaust in the mail today its so light compared to the stock one!!!
So you went with the .85 springs, how heavy are you? I think I need to go with the .90 I am 225lb
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Old December 27th, 2015, 11:37 AM   #29
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There was another thread here, a while back, where we were debating the need for venting of the reservoir (tube) as the fluid is pushed into the caliper.

The question being how that system would allow movement of the fluid level in the tube without letting air in. A regular reservoir has an expandable seal that is drawn down as the fluid level drops, but doesn't allow air into the system.

That system (sealed tubing) doesn't, so a vacuum is created inside the tube as your apply the brake.
thats why I went with the HRC kit. the bung supposedly has a way to release the vacuum.
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Old December 28th, 2015, 07:22 AM   #30
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So you went with the .85 springs, how heavy are you? I think I need to go with the .90 I am 225lb
I am about 170-75 without gear. I am worried that the .85 wont be stiff enough but im sure it'll be light and day compared to what i was riding haha.
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Old December 28th, 2015, 07:23 AM   #31
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thats why I went with the HRC kit. the bung supposedly has a way to release the vacuum.
"supposedly" haha. do you have the kit yet?
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Old December 28th, 2015, 07:24 AM   #32
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There was another thread here, a while back, where we were debating the need for venting of the reservoir (tube) as the fluid is pushed into the caliper.

The question being how that system would allow movement of the fluid level in the tube without letting air in. A regular reservoir has an expandable seal that is drawn down as the fluid level drops, but doesn't allow air into the system.

That system (sealed tubing) doesn't, so a vacuum is created inside the tube as your apply the brake.

I will look into this once i get it mounted back on the bike. I dont use my rear brakes at all except if i am in the grass. As long as i have some stopping ability ill be happy haha.
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Old December 28th, 2015, 08:14 AM   #33
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Went to work on the bike some yesterday but kept getting distracted, but did walk out and map a dirt bike course on the 50 acre farm where i keep my bike

I did check my valves yesterday though... all are tight so i get to start my research on the whole shimming process. Found a good walk through on here that i plan on using after i read all the comments.
https://www.ninjette.org/forums/showthread.php?t=9924
https://www.ninjette.org/forums/showthread.php?t=104729

Cylinder 1 Spec: Exhaust (0.0087 ~0.0114 in.) Intake (0.0059 ~0.0094 in.)
Intake .006
Intake .006
Exhaust .006
Exhaust .007

Cylinder 2
Intake .007
Intake .007
Exhaust .006
Exhaust .004

Since where i am working on my bike is an unfinished basement i brought my engine with me to my apartment to do the valves. Don't want the valve cover off and cams out for that long in that dusty place, plus the lighting sucks. I think its happy in its tire in my apartment haha

Also did some work with the fairing stay, decided that i am just going to modify the stock one for the time being. Once the rest of the bike is finished ill make a new one that is much lighter.
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Old December 28th, 2015, 08:34 AM   #34
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Oh and Racetech springs and gold valves ordered.... ok i need to stop spending money!!!


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Old December 28th, 2015, 08:48 AM   #35
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No truer things have been said haha
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Old December 28th, 2015, 10:22 AM   #36
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What size ID hose did you buy? I want to do this to my wera bike. For the vacuum issue, just make a note of where the level is and top it off every couple races to release the vacuum.

I'm 175 and have .85 with emulators and love them. Never had issues with the front except for running out of tire
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Old December 28th, 2015, 11:16 AM   #37
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What size ID hose did you buy? I want to do this to my wera bike. For the vacuum issue, just make a note of where the level is and top it off every couple races to release the vacuum.

I'm 175 and have .85 with emulators and love them. Never had issues with the front except for running out of tire
I dont remember off the top of my head what it is but i can check when i get home today. Ok thats good to hear... yea ive gotten close to running out of front on bt003s and that scared me.. Since having the alpha13s i still have like a quarter inch on both sides


Got my wheel bearings replaced on my lunch break... Crazy how easy bearings are when you have the right tools
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Old December 28th, 2015, 04:25 PM   #38
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Not the OP (mea culpa), but the Tygon tubing I used on my bikes is 5/16" ID, 7/16" OD. Fits happily on the ninjette and the CBR. No issues so far.
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Old December 28th, 2015, 04:46 PM   #39
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Not the OP (mea culpa), but the Tygon tubing I used on my bikes is 5/16" ID, 7/16" OD. Fits happily on the ninjette and the CBR. No issues so far.
How long is your tube?

...seriously! Perhaps there’s enough flex in a longer tube to allow for the changing fluid volume.

...I have no idea how to rewrite that to eliminate the double entendres!
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Old December 28th, 2015, 04:52 PM   #40
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Can y'all post a picture how you have it hooked up on the ninja?
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