Customizing a 2001 250

[DannoXYZ]

Hey, what coating & colour is that on flywheel cover?

[punishum808]

Originally Posted by DannoXYZ

Hey, what coating & colour is that on flywheel cover?

.
Its a powder coat, some tan color with a matte clear.

[punishum808]

So this is the complete motor. Still a lot of work on the chassis and custom parts that are being fabricated.
.
Stay Tuned.
.
ALoooooHA, Book UM Danno

[punishum808]

More custom pieces than you can imagine.
.
More than has ever been done before.
.
A custom linkage that has roller bearings, anodized AND is half a pound LIGHTER.
.
.

[Guaire]

Originally Posted by punishum808

More custom pieces than you can imagine.
.
More than has ever been done before.
.
A custom linkage that has roller bearings, anodized AND is half a pound LIGHTER.
.
.

Looks like a super-motor.
The custom linkage doesn't cross over to the stock location, I assume?!

[punishum808]

Originally Posted by Guaire

Looks like a super-motor.
The custom linkage doesn't cross over to the stock location, I assume?!

.
Its a direct replacement. Thanks to Danno I used a Newgen swingarm set up.
.
.

[punishum808]

The axles and pivot were custom made. Combined it lost nearly 2.5 pounds.
.
.

[punishum808]

Custom brace . . .
.
.

[DannoXYZ]

Wow, that's a piece of art!!! Original piece is solid hunk of steel! Very agricultural... but gets job done! So when you opening on-line store selling all these goodies?

[punishum808]

Test fit the new brace. It fit like a glove. We also know the dimensions for Newgen front ends too.
.
.

[punishum808]

Test fitting all the things up front.
.
.

[punishum808]

The weight of even the triple top retaining bolt is very heavy. So this is what we came up with.
.
All our pieces are anodized. This is why it has an iridium look.
.
.
.

[punishum808]

This triple tree top is 5 ounces lighter than stock.
.
.

[punishum808]

The official fuel system for our 2 wheeled projects on PunishUM Motorsports on Motortrend TV is the industry leaders 'Lectron Fuel Systems'.
.
This is the first set of their latest technology, the Billetron series with Power Jets that was custom built for our shows 250 Ninja.
.
Stay Tuned as this build just keeps getting better and better.
.
Mahalo

[punishum808]

So the red bolt is one you can pick up on Ebay, verses the one we had made. The one we made is -5 grams lighter and a better quality aluminum from 7050 billet stock.
.
.

[csmith12]

[punishum808]

Originally Posted by csmith12

.

[punishum808]

So we had tried to use the generic alum top bolt from ebay but still prefer the custom one made.
.
Changes the whole look completely. And it shaved off -5 ounces.
.
.
.

[punishum808]

Trial fitting the custom built Lectron Fuel Systems carbs for the 250 Ninja.
.
This is a one off set and they machined it to fit the stacks we made.
.
.

[punishum808]

Due to the size of the bowls on a Billetron Lectron carb the oem boots will not work. As you can see from this pic there is No Way it will mount.
.
.

[ducatiman]

More specific info required....is spacing between carbs adequate to allow mounting? NOPE, unfortunatlely too wide, back to the drawing board.

[punishum808]

Originally Posted by ducatiman

More specific info required....is spacing between carbs adequate to allow mounting? NOPE, unfortunatlely too wide, back to the drawing board.

.
Stay tuned for future posts.

[punishum808]

When ever working with anything never done before you have to accept that things are just not going to fall into place.
.
So I took a look at my 1428, 8 second, 200 hp dragbike to point me in the right direction.
.
Btw, these Miks are being replaced with fresh Lectrons also. They made them with clear bowls, Power Jets and the Lectron boots as well.
.
The Magura throttle has less than one inch of travel from 0 to wfo.
.
.
.

[punishum808]

.
So i figured it out and now the custom Lectrons will work.
.
.
.

[DannoXYZ]

Oohh. aaaahhh... drool...

[punishum808]

Originally Posted by DannoXYZ

Oohh. aaaahhh... drool...

.
Mahalo
.
.

[punishum808]

.
.
There hasnt been a nice and one that works manual tensioner for a Pre Gen.
.
So guess what? We made one.
.
.

[punishum808]

Experimenting with the swingarm.
.
We already have a better than stock caliper but the aftermarket bracket did NOT provide the proper clearance. Btw, it stated that it was made for this exact application. Unfortunately it wasn't as advertised.
.
So now we are designing our own one of a kind bracket to get the proper caliper to wheel clearance.
.
We are also designing our own axle blocks as the ebay one which is nice as it holds a slider but its thickness is much more than the stamped oem one.
.
.

[punishum808]

.
.
With the custom fender we also had to make some custom fasteners as well. A lot of cutting to get the fender to sit correctly had to be done so things like tire warmers can be used on the racing slicks.
.
.
.

[superkain]

Very nice!

[punishum808]

Originally Posted by superkain

Very nice!

.
Mahalo

[punishum808]

.
More Ti as even the motor mount bolts, shifter bolts, every nut or bolt is ti/22 or al/13.
.
.

[punishum808]

.
Silicone hoses require proper clamps. If you use the off the shelf clamps from your auto parts store you will damage silicone hoses in the long run.
.
.

[punishum808]

ALoooooHA
.
Its been a few months but the progress still continues.
.
So the carbs spacing has been solved. The attention to detail was necessary to be able to over come the obstacles when its never been done before.
.
.

[punishum808]

ALoooHA
.
So now test fitting the new radiator and will be mounting an external oil cooler too that will have an fittings and braided lines. All the bolts are aluminum.
.
Test with the bodywork on and it all fit nice and tidy.
.
.

[DannoXYZ]

So awesome!!!

Ever think about magnesium valve and case covers???

[punishum808]

Originally Posted by DannoXYZ

So awesome!!!

Ever think about magnesium valve and case covers???

.
That would be cool but if you don't work in that material all the time it is dangerous.
.
"It provides a hazard for CNC machinists: the chips and dust from machined magnesium are highly flammable."
.
.