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Old July 23rd, 2017, 05:43 PM   #41
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New frame and seat pan. It makes the whole seat sit perfectly flat and level



Nice job. By the way, Rust-Oleum 7515 Aluminum is a perfect match for that swingarm.

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Old July 23rd, 2017, 05:49 PM   #42
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Yeah I need to just hit it with something to fill that rusted area. I might tear this thing apart in the winter and clean it all out even more thoroughly.
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Old July 24th, 2017, 05:27 PM   #43
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So since I couldnt get much done in the garage today I decided to do whatever I could indoors. I brought in the gauge cluster and dropped it into the new mount. This thing is mint, its a block of aluminum with acrylic over it and the gauges in a symmetrical layout. The attention to detail on this is above and beyond.














The finished product is very cool. I cant wait to get it on the bike later this week or next.
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Old July 24th, 2017, 05:42 PM   #44
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That does look very nice, Tiago.
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Old July 24th, 2017, 11:17 PM   #45
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Nice! I like the layout.
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Old July 25th, 2017, 05:13 PM   #46
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Got a chance to waterproof and stain the seat. They were nice enough to include that in the box. Brought out the rich color of the seat.





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Old July 25th, 2017, 05:44 PM   #47
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I'm starting to think that the high price of their stuff is due to the high quality.
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Old July 25th, 2017, 05:51 PM   #48
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Yeah its definitely pricey for sure, but the quality that it brings really stands out. I also like that its a "small company" and made in the US, if that means anything to anyone anymore. The fact that I bought the bike for $500 allows me to have a cafe racer for about 2k.
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Old July 25th, 2017, 07:56 PM   #49
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Got a chance to waterproof and stain the seat. They were nice enough to include that in the box. Brought out the rich color of the seat.





Well, excuse meee! A leather seat. Very nice and apparently 1st class leather working.

Classy!

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Old August 14th, 2017, 01:53 AM   #50
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This is awesome! Great pics and attention to detail. Keep the pics coming
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Old August 15th, 2017, 10:45 AM   #51
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After some work on this bike, it was running ok but not the way it should. Something told me to check the valves and sure enough there was almost no clearance on them. Managed to take it all apart but will only be able to adjust them this week. Then removing the carbs to bench sync
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Old August 16th, 2017, 03:23 PM   #52
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Adjusted the valves, surprisingly simple if you have all the tools that you need. I bench synced the carbs and reinstalled everything. Installed the carbs and tanks to fire it up. Fires up perfectly, smooth non-hunting idle. Moves thru the rpm's smoothly now and actually acts like it wants to move. I left the idle screw to 3 turns out till I have enough time to take it out for a long ride to warm it up and set the screws.
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Old August 16th, 2017, 03:31 PM   #53
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Heres some photos since its been a while, most of the work is completed on this, with little things here and there.

Started the lights and wiring. Turns, brake light, and license plate bracket with light











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Old August 21st, 2017, 01:20 PM   #54
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Got the vinyl wrap done on some of the parts and needless to say Im not pleased. Its a terrible method to use, when you can just paint it. My laziness ended up making more work for me in the long run Stretching this over all the round parts was such a hassle it didnt pay off.

The side covers included in this bike really tidy up the sides, my only gripe is they get scratched up from boots and pants and anything that touches it. Also the tail makes the shape of this bike totally different. It looks great.







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Old August 22nd, 2017, 08:09 AM   #55
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I got the airbox apart and out



Got it all cleaned up

Was the air box a pain in the ass to remove. I love the ninjette and everything about it's design but I find the air box deign to be extremely terrible and perhaps flawed? I cannot possibly be the only one to have issues removing it?
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Old August 22nd, 2017, 08:13 AM   #56
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Was the air box a pain in the ass to remove. I love the ninjette and everything about it's design but I find the air box deign to be extremely terrible and perhaps flawed? I cannot possibly be the only one to have issues removing it?
You have to split it. It won't clear the frme otherwise if I'm not mistaken. There are about 10 screw if I remember right. Split it and make sure you keep track of everything. Then one piece at a time lift it out the frame.
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Old August 22nd, 2017, 08:17 AM   #57
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You have to split it. It won't clear the frme otherwise if I'm not mistaken. There are about 10 screw if I remember right. Split it and make sure you keep track of everything. Then one piece at a time lift it out the frame.
You are right. Anyway, this is going to be one bad ass looking bike. I definitely enjoyed reading and catching up on your progress. Can't wait to see the finished product. I love that dash. Where did you get it? I have a 2001 I've got some ideas for. Thanks
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Old August 22nd, 2017, 08:49 AM   #58
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You are right. Anyway, this is going to be one bad ass looking bike. I definitely enjoyed reading and catching up on your progress. Can't wait to see the finished product. I love that dash. Where did you get it? I have a 2001 I've got some ideas for. Thanks
The dash came with the kit. I wouldnt mind having an aftermarket digital one, but I dont think it maintains the theme and this was included in the kit I purchased.
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Old August 23rd, 2017, 06:06 PM   #59
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Yeah, analog meters and bulbous headlight are more aligned with the Bobber theme.

I have an older KLR-650 dualsport where the original faring and meters were destroyed (stolen by highskool jerkkoffs then recovered by cr@ck-smoking tow truck monkey).

So I went with the trailtech headlight and digi meters (X2-Lighting and Vapor meter). This combo shaved about 20 lbs of the fat-@ssed KLR (~360 lbs oem). Plus taking the weight off at the highest point on the bike changed the handling behavior in the rough -a positive change to be sure.

But, your bike and vision are in a different paradigm. I think that too few riders do the Bobber theme in a clean fashion -they end up with very bad aesthetic (size/shape of the lines and curves are just awkward) or very poor execution (crappy wiring, infinished mounts, loose and poorly fitted bits).

So far, yours is on-track to be a top-line execution. Keep with your vision !!!

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Old August 25th, 2017, 10:19 AM   #60
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So after removing the clutch plates, oiling them and reinstalling them, I was having issues starting the bike. Turns out the clutch plunger was too loose to allow the bike to start.

While I cursed myself out over it, it did help me find some issues. I ran the battery low and had to place it on a tender overnight (no big deal) and flooded the bike with gas. This led to having to pop the crankcase hose plug and when I went to drain the carbs...GUNK...I guess the tank wasnt as clean as I thought. I then reached out to the help of @ducatiman to get the carbs back in top shape in case my work wasnt up to par. Sent them out yesterday and hope to get them back soon as he is known for his quick turnaround and amazing work
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Old August 25th, 2017, 11:36 AM   #61
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I trust you now have a good inline filter between the tank and carbs.
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Old August 25th, 2017, 12:31 PM   #62
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I trust you now have a good inline filter between the tank and carbs.
Once the carbs are back, one will be installed. Any advice to which? I know it needs to be gravity fed and needs to keep up with the flow correct?
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Old August 25th, 2017, 01:41 PM   #63
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Yes, but the flow is not high at all. I prefer pleated paper filters to sintered metal ones, because I've had particles get through the metal type and clog a jet. There are high quality, fine sintered metal filters though. The small pleated paper type works fine for me, but if you might have fine rust or silt in the tank, carry a spare filter. They work well, but if they trap enough stuff, they'll clog. I had that happen this spring, and without a spare I had to backflush mine by filling it with gasoline and blowing through it backwards several times.
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Old August 25th, 2017, 01:57 PM   #64
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Yes, but the flow is not high at all. I prefer pleated paper filters to sintered metal ones, because I've had particles get through the metal type and clog a jet. There are high quality, fine sintered metal filters though. The small pleated paper type works fine for me, but if you might have fine rust or silt in the tank, carry a spare filter. They work well, but if they trap enough stuff, they'll clog. I had that happen this spring, and without a spare I had to backflush mine by filling it with gasoline and blowing through it backwards several times.
I picked up 2 of these on amazon. Will these do?

https://www.amazon.com/Outlaw-Racing...ne+fuel+filter
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Old August 25th, 2017, 02:19 PM   #65
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I picked up 2 of these on amazon. Will these do?

https://www.amazon.com/Outlaw-Racing...ne+fuel+filter
They should be fine. I found that a Briggs and Straton paper filter and hose clamps fit the Ninja perfectly.

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Old August 25th, 2017, 03:42 PM   #66
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I picked up 2 of these on amazon. Will these do?

https://www.amazon.com/Outlaw-Racing...ne+fuel+filter
That's the sintered metal type that let junk though and clogged the main jet in my DT100. You can spot the pleated paper type because of the... pleated paper.
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Old August 25th, 2017, 05:40 PM   #67
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That's the sintered metal type that let junk though and clogged the main jet in my DT100. You can spot the pleated paper type because of the... pleated paper.
Thanks TJ. I've used that type in the past - no more.

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Old August 25th, 2017, 05:48 PM   #68
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I'll try to return it. I'll get a paper one sent from Amazon. Recommendations?
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Old August 25th, 2017, 05:56 PM   #69
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I'll try to return it. I'll get a paper one sent from Amazon. Recommendations?
Go to your local hardware store, Lowes, Home Depot, Tractor Supply and buy the B&S filter. It fits perfectly and you get hose clamps that work unlike those cheesy Jap. wire clamps.

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Old August 25th, 2017, 05:59 PM   #70
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As I posted above, get two and carry a spare. They're very inexpensive, so if one clogs during a ride, you can just pop a new one on.
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Old August 25th, 2017, 06:31 PM   #71
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Received carbs today and finished this evening...came out good. Pelican contacted. I'm whooped.
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Old November 12th, 2017, 05:19 PM   #72
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So after running into issues and kind of mocking up all the body work, I finally got the carbs running right. That is after a send off to Ducatiman. He was a godsend. The issue now is that its too cold to be worth a damn running. Its clearly super lean.

I will use this winter to tear it all apart. I mean everything. Engine off the frame type teardown. Doing to touchup or make little improvements wherever I can, and finally give this thing a proper paintjob. Then Im going to get into the nitty gritty of learning to jet a bike. Should be a good time, the only thing that sucks is finding a happy medium for temperature changes. I def have my work cut out for me. Any assistance along the way is appreciated as always
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Old November 12th, 2017, 05:27 PM   #73
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I think this is where I left off. I hope to do a better job as all these parts come off, and documenting the process

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Old November 12th, 2017, 06:22 PM   #74
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Wow, that looks great! Any front angle shots?
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Old November 19th, 2017, 04:11 PM   #75
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This is the update, Ive started stripping down the bike to basically build it all back up. The goal is to go thru it, doing any maintenance needed, deep cleaning, polishing, and doing any functional upgrading where I can (sprockets, chain etc)

My goal is to drain the coolant and getting the engine and radiator off the frame so that I can start working on both. Right now Ive taken off the body panels, lights, brakes, rearsets, carbs (going to be jetted, if I can figure it out.), airbox. I dont want to pull the harness off the frame because it looks quite overwhelming no matter how basic the bike may be. I will be cleaning up the connections and making sure everything works as it should.
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Old November 20th, 2017, 01:50 PM   #76
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There is like a 45% chance I know what I'm doing and a good chance I'll have spare parts that I shouldn't have, when all of this is said and done.

But at least the motor is out of the frame. Not as hard as imagined, just need to make sure I keep track of everything.



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Old November 20th, 2017, 03:47 PM   #77
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I like to take a bunch of photos in case I can't remember how things were before I took them apart.
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Old November 20th, 2017, 04:01 PM   #78
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I like to take a bunch of photos in case I can't remember how things were before I took them apart.
Im trying but I wouldn't be surprised if I reach out to you and the other gurus for help, when I eventually piece this back together.
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Old November 20th, 2017, 04:36 PM   #79
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I've worked on a few motorcycles in depth before, but I haven't done much to my 250 other than routine maintenance and some cosmetic stuff. I'll be learning from you.
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Old November 20th, 2017, 06:55 PM   #80
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I've worked on a few motorcycles in depth before, but I haven't done much to my 250 other than routine maintenance and some cosmetic stuff. I'll be learning from you.
I actually have a Triumph Speed Triple that is my main bike, I did all the work to it myself, but nothing as in depth as this bike. Im not too worried if the bike is down for a while since I can still ride the Triumph. And for the 200 or so dollars this bike cost me I couldnt have picked a better bike to tear down.
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