Ninja upgrades = ZZR250 Super Ninja :) - Page 2

Mohawk · November 29th, 2016, 12:10 PM

Well the bad news is I was made redundant last week

The good news is apart from time spent looking for a new job I have a lot of free time, so finally got the front calipers stripped & reassembled over the last couple of days & just finished putting the bike back together

Whilst I was waiting, I finally fixed a small leak from the oil cooler & whilst looking for a replacement exhaust, I found an original set of headers in VGC, so did a deal with the seller & fitted those to replace the rusty & holed on one side original headers.

For anyone looking for numbers, the stock headers are 31mm OD, 26mm ID, they are made from two 1mm wall tubes one inserted inside the other before forming. The exhaust port flange area is 40mm OD, the exhaust port is 29mm inside the flange area.
The removed crushed seal is 30mm ID & 39mm OD. The standard cans have a 20mm ID exit hole & the cross header balance pipe is 20mm ID.

So a good exhaust for maximum flow would have a minimum ID of 30mm. I'll be making a custom exhaust 2-1 header to go with the 282cc big bore kit.

All good now, so will organise an MoT (annual inspection) ASAP & then get some saddle time. It's minus 2C here at the mo, so will have to wait a few days for the weather to warm up. I'll get some pictures too.

CaliGrrl · November 29th, 2016, 12:50 PM

Well the job thing sucks but it sounds like your bike's in good shape!

Looking forward to pictures.

Mohawk · December 1st, 2016, 08:46 AM

Still sub zero & foggy here today, so no bike riding

Might be next week before weather warms a little.

Mohawk · December 5th, 2016, 03:25 PM

Well the bike just passed annual inspection today, so need to tax it then all good to go.
I'll try & get it dyno'd then when the weather gets really crap, I'll do the big bore to 282cc

Mohawk · December 19th, 2016, 03:11 PM

Took the bike for a 40 mile blast today, it was only 7c & a bit damp. Bike worked a treat, flat out or cruising, no issues, fulling is spot on very happy that the ignition gremlins are gone

Tried to organise the dyno run, but guy was not answering his phone.

Alex · January 15th, 2017, 03:09 PM

Ducremus · November 29th, 2021, 07:19 PM

I'm new to this site, and new to EX250's, and am not well versed in electronics of any kind, but I've done two COP conversions on 2 different EX500's. I have no idea if the 250's and 500's have the same electronics, but I know on the 500's, when you do the COP conversion you must change plugs to the Iridiums because they have a much weaker spark and can take advantage of the lower power coming out of the weaker Honda 600 coils. If you don't change the plugs it doesn't work very well at all. Both my 500's ran great after the COP/Iridium plug changeover. Could that be the answer you're looking for? BTW, is there a write up on the conversion for the 250? I looked but did not find.

DannoXYZ · November 29th, 2021, 08:04 PM

Here's guide of sorts. Just matter of connecting COP harness to original coil wire. Most people just use 1/4" spade connectors. It's extremely important to get COP with similar primary-coil impedance as stock coils. There's posts about lower-resistance units drawing too much power and overheating ignitor. Might be source of some under-powered COP conversions. Typically you'll find COP has higher power and you can increase plug-gap for hotter spark.

https://www.ninjette.org/forums/showthread.php?t=123425

Ducremus · November 29th, 2021, 08:19 PM

Quote:

Originally Posted by DannoXYZ

Here's guide of sorts. Just matter of connecting COP harness to original coil wire. Most people just use 1/4" spade connectors. It's extremely important to get COP with similar
primary-coil impedance as stock coils. There's posts about lower-resistance units drawing too much power and overheating ignitor. Might be source of some under-powered COP conversions. Typically you'll find COP has higher power and you can increase plug-gap for hotter spark.

https://www.ninjette.org/forums/showthread.php?t=123425

Thanks! Just what I was looking for.

DannoXYZ · November 29th, 2021, 08:41 PM

Quote:

Originally Posted by Ducremus

Thanks! Just what I was looking for.

you're welcome! Found another more detailed guide:
https://www.ninjette.org/forums/blog.php?b=8379
https://www.ninjette.org/forums/showthread.php?t=118112

Ducremus · November 30th, 2021, 01:57 PM

Thank you! I'm learning new stuff every day on this site!

December 1st, 2016, 08:46 AM	#43
Mohawk ninjette.org guru Name: Chris Location: Bristol, UK Join Date: Feb 2016 Motorcycle(s): ZZR250, VFR800 Posts: 477	Still sub zero & foggy here today, so no bike riding Might be next week before weather warms a little. Last futzed with by Mohawk; December 1st, 2016 at 10:59 AM.

January 15th, 2017, 03:09 PM	#46
Alex ninjette.org dude Name: 1 guess :-) Location: SF Bay Area Join Date: Jun 2008 Motorcycle(s): '13 Ninja 300 (white, the fastest color!), '13 R1200RT, '14 CRF250L, '12 TT-R125LE Posts: Too much. Blog Entries: 7	__________________________________________________ Montgomery Street Motorcycle Club / cal24.com / crf250l.org / ninjette.org ninjette.org Terms of Service Shopping for motorcycle parts or equipment? Come here first. The friendliest Ninja 250R/300/400 forum on the internet! (especially Unregistered)

November 29th, 2021, 07:19 PM	#47
Ducremus ninjette.org member Name: Rich Location: NE Join Date: Nov 2021 Motorcycle(s): 1994 EX500, 2006EX250 Posts: 12	COP's I'm new to this site, and new to EX250's, and am not well versed in electronics of any kind, but I've done two COP conversions on 2 different EX500's. I have no idea if the 250's and 500's have the same electronics, but I know on the 500's, when you do the COP conversion you must change plugs to the Iridiums because they have a much weaker spark and can take advantage of the lower power coming out of the weaker Honda 600 coils. If you don't change the plugs it doesn't work very well at all. Both my 500's ran great after the COP/Iridium plug changeover. Could that be the answer you're looking for? BTW, is there a write up on the conversion for the 250? I looked but did not find.

November 30th, 2021, 01:57 PM	#51
Ducremus ninjette.org member Name: Rich Location: NE Join Date: Nov 2021 Motorcycle(s): 1994 EX500, 2006EX250 Posts: 12	Thank you! I'm learning new stuff every day on this site!
	1 out of 1 members found this post helpful.

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November 29th, 2016, 12:10 PM	#41
Mohawk ninjette.org guru Name: Chris Location: Bristol, UK Join Date: Feb 2016 Motorcycle(s): ZZR250, VFR800 Posts: 477	Well the bad news is I was made redundant last week The good news is apart from time spent looking for a new job I have a lot of free time, so finally got the front calipers stripped & reassembled over the last couple of days & just finished putting the bike back together Whilst I was waiting, I finally fixed a small leak from the oil cooler & whilst looking for a replacement exhaust, I found an original set of headers in VGC, so did a deal with the seller & fitted those to replace the rusty & holed on one side original headers. For anyone looking for numbers, the stock headers are 31mm OD, 26mm ID, they are made from two 1mm wall tubes one inserted inside the other before forming. The exhaust port flange area is 40mm OD, the exhaust port is 29mm inside the flange area. The removed crushed seal is 30mm ID & 39mm OD. The standard cans have a 20mm ID exit hole & the cross header balance pipe is 20mm ID. So a good exhaust for maximum flow would have a minimum ID of 30mm. I'll be making a custom exhaust 2-1 header to go with the 282cc big bore kit. All good now, so will organise an MoT (annual inspection) ASAP & then get some saddle time. It's minus 2C here at the mo, so will have to wait a few days for the weather to warm up. I'll get some pictures too.

November 29th, 2016, 12:50 PM	#42
CaliGrrl ninjette.org certified postwhore Name: Kerry Location: Ventura, CA Join Date: Jan 2016 Motorcycle(s): Ninja650 Posts: A lot. MOTM - Apr '18, Apr '17, Apr '16	Well the job thing sucks but it sounds like your bike's in good shape! Looking forward to pictures.

December 5th, 2016, 03:25 PM	#44
Mohawk ninjette.org guru Name: Chris Location: Bristol, UK Join Date: Feb 2016 Motorcycle(s): ZZR250, VFR800 Posts: 477	Well the bike just passed annual inspection today, so need to tax it then all good to go. I'll try & get it dyno'd then when the weather gets really crap, I'll do the big bore to 282cc

December 19th, 2016, 03:11 PM	#45
Mohawk ninjette.org guru Name: Chris Location: Bristol, UK Join Date: Feb 2016 Motorcycle(s): ZZR250, VFR800 Posts: 477	Took the bike for a 40 mile blast today, it was only 7c & a bit damp. Bike worked a treat, flat out or cruising, no issues, fulling is spot on very happy that the ignition gremlins are gone Tried to organise the dyno run, but guy was not answering his phone.

November 29th, 2021, 08:04 PM	#48
DannoXYZ ninjette.org certified postwhore Name: AKA JacRyann Location: Mesa, AZ Join Date: Dec 2011 Motorcycle(s): CB125T CBR250R-MC19 CBR250RR-MC22 NSR350R-MC21 VF500F CBR600RR SFV650 VFR750F R1M ST1300PA Valkyrie-F6C Posts: A lot. MOTY - 2018, MOTM - Nov '17	Here's guide of sorts. Just matter of connecting COP harness to original coil wire. Most people just use 1/4" spade connectors. It's extremely important to get COP with similar primary-coil impedance as stock coils. There's posts about lower-resistance units drawing too much power and overheating ignitor. Might be source of some under-powered COP conversions. Typically you'll find COP has higher power and you can increase plug-gap for hotter spark. https://www.ninjette.org/forums/showthread.php?t=123425