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Old March 5th, 2016, 04:33 PM   #1
spent_too_much
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94 EX250 build - take 2

I started a build thread about a year ago, and after a little over a month, the project stagnated. I have a renewed drive to complete it, but in a different direction than last year.

Link to previous build...

https://www.ninjette.org/forums/showthread.php?t=228089

Where we stand today...
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File Type: jpg 20160305_181639.jpg (76.9 KB, 25 views)
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Old March 5th, 2016, 04:37 PM   #2
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This is the direction that I am headed this time around. What is pictured as red will be blue, and what is black will be a dark grey. I just need to find the exact colors in a spray paint. I'm unsure about the color for the wheels - both matching grey? Both matching blue? Or, one of each?
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File Type: jpg slant cowl red and blk btm.jpg (127.6 KB, 27 views)
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Old March 5th, 2016, 04:53 PM   #3
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Blue wheels!!
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Old March 5th, 2016, 04:59 PM   #4
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Color match the wheels to the front/rear paint scheme.
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Old March 5th, 2016, 05:18 PM   #5
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I vote a third color for the wheels, maybe a light gray.
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Old March 6th, 2016, 07:03 AM   #6
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So, like me, 2 votes for blue front wheel, and grey rear? Once I get the bike mostly painted, and reassembled, I'll take photos all 3 ways, and then make a final decision. Thanks for the input!
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Old March 6th, 2016, 07:07 AM   #7
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Any suggestions on filling in this void? It is where the right hand side turn signal bolts on. The previous owner made a faux carbon fibre plate, bolted over it. Not a bad job, but not my style.

I have another lower engine fairing ( disfigured due to heat? ) to use for bits of plastic. I thought I might try to solder weld bits together, then apply a coat of epoxy, then sand to shape.

This pic is upside down. It is the main upper fairing.
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Old March 6th, 2016, 07:13 AM   #8
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I will also need new tires. I did some research on Ninja 250 faq website, and have decided, based on cost, to go with Pirelli Diablo O.E. Scooter Tire - 130/80 16 rear, and 100/80 16 front. The best price that I can find so far is $150 shipped. Is there a better deal to be found?

I already have Pirelli MT75s on my other 250, and the rear 120/80 16 is too narrow looking.
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Old March 6th, 2016, 03:19 PM   #9
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Quote:
Originally Posted by spent_too_much View Post
I will also need new tires. I did some research on Ninja 250 faq website, and have decided, based on cost, to go with Pirelli Diablo O.E. Scooter Tire - 130/80 16 rear, and 100/80 16 front. The best price that I can find so far is $150 shipped. Is there a better deal to be found?

I already have Pirelli MT75s on my other 250, and the rear 120/80 16 is too narrow looking.
Let me know how you like the Diablo's compared to the MT75's, I love my MT75's but I was considering the Diablos.
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Old March 6th, 2016, 05:22 PM   #10
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Wheels I went naked on mine, took a sandblaster to them. Purple wasn't gonna cut it.

Tires I've used Kenda K671, and Bridgestone BT45. Both excellent choices the Kendas are inexpensive, excellent wet weather performance, and last a lot of miles perfect for commuting.

Good luck on your second attempt, I'm lucky enough to have the free time needed to do mine, so it only took about month to do the bulk of the work. It's maiden long distance voyage was soon after, 700 miles in a single day.

Work performed so far,


Cut and set sag front fork springs(springs from a Ninja 500 1st generation, rate is .85kg/mm )

Replace fork oil 15wt synthetic

Install new fork seals and dust caps

Replace rear shock(zx600c)

Replace shock oil 15wt synthetic

Change gears +1/-2(15/43)

Rebuild/tune carbs, adjust idle mixture

K&N air filter

New brake pads F&R EBC extreme HH

New Wave front rotor

Used OEM rear rotor

Rebuilt calipers

Modified OEM seat(gel/foam insert, Custom Seat Creation cover solo line cf silver/cf metal, heated kit)

Extra heavy bar ends(3"/23oz)

Heated grips w/ foam covers

Touring windscreen / 7 JuRock 18" 73%tint w/ flip

Shorter bar risers(OEM ZX600c, lower bars about 1 1/2")

Removed paint from rims, bare aluminum

Bridgestone BT-45s w/ Dynabeads

Stainless steel allen head fasteners

Stainless steel braided brake lines

Shorty adjustable levers

HD clutch springs

Charge/voltage LED indicator

LED clock

HID headlight(55w 5k)

Replaced all other bulbs with CREE LEDs

DIY integrated tail light kit w/clear lens

DIY rear fender elimination

DIY licence plate mount(LEDs to illuminate the plate/red LEDs tied into brake light)

Brake light modulator

Maintenance free gel battery

Compact air horn

2007 Complete OEM fairing set silver

Genuine imitation carbon fiber wrap misc parts

Reflective custom graphics ZX-2R silver

Reflective custom graphic NINJA red(taillight lens)

Reflective rim tape silver

Electronic turn indicator relay

Replace front side reflectors with flush mount turn indicators LEDs

Installed rearview camera system

Installed oil cooler

Strip paint off grab handle, bare aluminum alloy.*

Custom reflective graphic "SERENITY" for windscreen silver

Aluminum chain guard from Suzuki Bandit 1200

Swing arm plugs from 08 Ninja 250

Mad Hornets Turn Signal Indicators w/duel color Cree LEDs(amber/white)

FH010 R/R modification

Digital gear indicator

Universal Rear View Side Mirror Rain Board Sun Visor Shade Shield

Kawasaki ZRX1200 lowered foot pegs

OEM upgrade shift spring

All this and full maintenance and rebuild everything else except the motor. I'm sure I'm forget some stuff, but you get the idea

SIDENOTE: is that a CBR500 chain guard I see in your parts photo?
Attached Images
File Type: jpg 6016638706719119010-1.jpg (176.1 KB, 17 views)
File Type: jpg 6016638619078174978-1.jpg (126.8 KB, 10 views)
File Type: jpg 6022723642614791778-1.jpg (212.6 KB, 10 views)
File Type: jpg wallpaper_1.jpg (114.1 KB, 17 views)
File Type: jpg 6096104756963134002-1.jpg (160.7 KB, 45 views)
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Old March 6th, 2016, 06:21 PM   #11
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Quote:
Originally Posted by Ghostt View Post
Wheels I went naked on mine, took a sandblaster to them. Purple wasn't gonna cut it.

Tires I've used Kenda K671, and Bridgestone BT45. Both excellent choices the Kendas are inexpensive, excellent wet weather performance, and last a lot of miles perfect for commuting.

Good luck on your second attempt, I'm lucky enough to have the free time needed to do mine, so it only took about month to do the bulk of the work. It's maiden long distance voyage was soon after, 700 miles in a single day.

Work performed so far,


Cut and set sag front fork springs(springs from a Ninja 500 1st generation, rate is .85kg/mm )

Replace fork oil 15wt synthetic

Install new fork seals and dust caps

Replace rear shock(zx600c)

Replace shock oil 15wt synthetic

Change gears +1/-2(15/43)

Rebuild/tune carbs, adjust idle mixture

K&N air filter

New brake pads F&R EBC extreme HH

New Wave front rotor

Used OEM rear rotor

Rebuilt calipers

Modified OEM seat(gel/foam insert, Custom Seat Creation cover solo line cf silver/cf metal, heated kit)

Extra heavy bar ends(3"/23oz)

Heated grips w/ foam covers

Touring windscreen / 7 JuRock 18" 73%tint w/ flip

Shorter bar risers(OEM ZX600c, lower bars about 1 1/2")

Removed paint from rims, bare aluminum

Bridgestone BT-45s w/ Dynabeads

Stainless steel allen head fasteners

Stainless steel braided brake lines

Shorty adjustable levers

HD clutch springs

Charge/voltage LED indicator

LED clock

HID headlight(55w 5k)

Replaced all other bulbs with CREE LEDs

DIY integrated tail light kit w/clear lens

DIY rear fender elimination

DIY licence plate mount(LEDs to illuminate the plate/red LEDs tied into brake light)

Brake light modulator

Maintenance free gel battery

Compact air horn

2007 Complete OEM fairing set silver

Genuine imitation carbon fiber wrap misc parts

Reflective custom graphics ZX-2R silver

Reflective custom graphic NINJA red(taillight lens)

Reflective rim tape silver

Electronic turn indicator relay

Replace front side reflectors with flush mount turn indicators LEDs

Installed rearview camera system

Installed oil cooler

Strip paint off grab handle, bare aluminum alloy.*

Custom reflective graphic "SERENITY" for windscreen silver

Aluminum chain guard from Suzuki Bandit 1200

Swing arm plugs from 08 Ninja 250

Mad Hornets Turn Signal Indicators w/duel color Cree LEDs(amber/white)

FH010 R/R modification

Digital gear indicator

Universal Rear View Side Mirror Rain Board Sun Visor Shade Shield

Kawasaki ZRX1200 lowered foot pegs

OEM upgrade shift spring

All this and full maintenance and rebuild everything else except the motor. I'm sure I'm forget some stuff, but you get the idea

SIDENOTE: is that a CBR500 chain guard I see in your parts photo?
Rearview camera system? What...?
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Old March 6th, 2016, 06:28 PM   #12
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Quote:
Originally Posted by HoneyBadgerRy View Post
Rearview camera system? What...?
Yup, but it's not working at the moment, cheap LCD screen+H2O=DEATH!!

But it was a handy thing to have, no more blind spot.
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Old March 6th, 2016, 06:31 PM   #13
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Quote:
Originally Posted by Ghostt View Post
Yup, but it's not working at the moment, cheap LCD screen+H2O=DEATH!!

But it was a handy thing to have, no more blind spot.
Couldn't you just... Turn around...? My riding style is way different than yours, but I never really felt like there was a blind spot on a motorcycle.
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Old March 6th, 2016, 06:41 PM   #14
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MOTM - Jun '17, May '16, Mar '15
Quote:
Originally Posted by HoneyBadgerRy View Post
Couldn't you just... Turn around...? My riding style is way different than yours, but I never really felt like there was a blind spot on a motorcycle.
Yea, I could and do, it was one of things to try out, the kit was cheap enough off eBay. And believe it or not it did come in handy Rearview camera install

It's like the Digital gear indicator I added, not a necessary part, but nice to have kind of thing, true FARKLES
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File Type: jpg 6061256658966962386.jpg (109.2 KB, 10 views)
File Type: jpg 6148227851316159906.jpg (128.6 KB, 18 views)
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Old March 6th, 2016, 06:50 PM   #15
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Quote:
Originally Posted by spent_too_much View Post
Any suggestions on filling in this void? It is where the right hand side turn signal bolts on. The previous owner made a faux carbon fibre plate, bolted over it. Not a bad job, but not my style.

I have another lower engine fairing ( disfigured due to heat? ) to use for bits of plastic. I thought I might try to solder weld bits together, then apply a coat of epoxy, then sand to shape.

This pic is upside down. It is the main upper fairing.
After cleaning up the edges a bit, I would attach a piece of paper flush on one side of the hole with spray adhesive or some other glue, fill in the void with ABS cement, and then sand.
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Old March 6th, 2016, 06:54 PM   #16
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Perhaps these might cover it up, and help the looks too

Mad Hornet's flushmount front turn signals /AsianCycle flush-mounts clones
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Old March 7th, 2016, 05:31 PM   #17
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Quote:
Originally Posted by Flying View Post
After cleaning up the edges a bit, I would attach a piece of paper flush on one side of the hole with spray adhesive or some other glue, fill in the void with ABS cement, and then sand.
I like that idea. Would I try to fill it all at once, or in segments? If all at once, I guess it would set as one piece.
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Old March 7th, 2016, 05:42 PM   #18
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http://faq.ninja250.org/wiki/Body_plastics_repair_guide
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Old March 8th, 2016, 04:23 AM   #19
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Quote:
Originally Posted by spent_too_much View Post
I like that idea. Would I try to fill it all at once, or in segments? If all at once, I guess it would set as one piece.
All at once, use a spreader. I'm thinking treat it like you would Bondo. I've never done it before, not quite sure how well the patch will fuse to the original plastic.
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Old March 8th, 2016, 11:34 AM   #20
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A great guide . Thank you.
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Old March 8th, 2016, 11:36 AM   #21
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Quote:
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All at once, use a spreader. I'm thinking treat it like you would Bondo. I've never done it before, not quite sure how well the patch will fuse to the original plastic.
I guess I could melt a few paper clips in to the original plastice, to have something for the "new" plastic to bond to? I'll just need to try and see where it goes. I plan to try this weekend.
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Old March 8th, 2016, 11:42 AM   #22
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Quote:
Originally Posted by Ghostt View Post
Perhaps these might cover it up, and help the looks too

Mad Hornet's flushmount front turn signals /AsianCycle flush-mounts clones
I'll go that route if the patching doesn't work. I wanted these for my other bike, 2 years ago, but the were discontinued. Glad to see them return!
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Old March 8th, 2016, 11:47 AM   #23
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IMO, I would use aluminum foil for the backing. The ABS cement won't stick to it.
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Old March 8th, 2016, 01:33 PM   #24
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Another option is keep checking eBay, I got a complete of plastics from an 07' for $200.00 shipped.

If you keep an eye out you might find an upper for cheap, and save time and aggravation.
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Old March 9th, 2016, 04:45 PM   #25
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Quote:
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Another option is keep checking eBay, I got a complete of plastics from an 07' for $200.00 shipped.

If you keep an eye out you might find an upper for cheap, and save time and aggravation.
Yeah. I thought of that. No good deals right now - either eBay or Craigslist...
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Old March 9th, 2016, 04:51 PM   #26
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Yeah. I thought of that. No good deals right now - either eBay or Craigslist...
Of your not in a hurry, patience is a virtue. It took me about 3 weeks to score my deal, so keep checking often, and don't hesitate to pull the trigger when you find one.

How much you willing to spend ? If you don't mind me asking.

Also don't forget the check the sale section here.
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Old March 9th, 2016, 06:11 PM   #27
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After searching many home improvement, department, and auto parts stores, I decided to try these these colors - based upon price, availability, and past experience:

Gloss Deep Blue
249114 - 12 oz. Spray
<img src="http://www.rustoleum.com/~/media/DigitalEncyclopedia/Product/RustoleumUSA/CBG/painters-touch-ultra-cover-2x/gloss/249114_0213_PTO_12oz_2xUltraCover_Gloss_DeepBlue.ashx" alt="Ocean Mist"/>

Gloss Dark Gray
249115 - 12 oz. Spray <img src="http://www.rustoleum.com/~/media/DigitalEncyclopedia/Product/RustoleumUSA/CBG/painters-touch-ultra-cover-2x/gloss/249115_0213_PTO_12oz_2xUltraCover_Gloss_DarkGray.ashx" alt="Ocean Mist"/>
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Old March 9th, 2016, 06:16 PM   #28
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Quote:
Originally Posted by spent_too_much View Post
I will also need new tires. I did some research on Ninja 250 faq website, and have decided, based on cost, to go with Pirelli Diablo O.E. Scooter Tire - 130/80 16 rear, and 100/80 16 front. The best price that I can find so far is $150 shipped. Is there a better deal to be found?

I already have Pirelli MT75s on my other 250, and the rear 120/80 16 is too narrow looking.
The best deal that I can find this week is Jet.com $126.28 shipped, with a first time buyer 15% discount. I have decided to go with Pirelli Diablo O.E. Scooter Tire - 130/80 16 rear, and 100/80 16 front. I don't need these until repair and paint are completed, so I might wait and see where prices go over the next few weeks.
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Old March 11th, 2016, 05:33 PM   #29
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I painted a couple of random parts today, to see how the paint would actually look... I don't like it

I might need to go with another color scheme.
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Old March 11th, 2016, 05:35 PM   #30
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I painted a couple of random parts today, to see how the paint would actually look... I don't like it

I might need to go with another color scheme.
I hope I like my paint scheme better. I already ordered all the paint.
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Old March 12th, 2016, 05:22 AM   #31
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For jets try PM @ducatiman
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Old March 12th, 2016, 06:50 PM   #32
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For jets try PM @ducatiman
Ghostt, I don't understand your reply?
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Old March 12th, 2016, 07:02 PM   #33
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I have been searching for alternate paint colors, within the $4 to $6 per spray paint can range, and am not finding any dark blue and dark grey combination that I like. I am considering an orange & flat black combo, where the orange would replace the red / blue, and flat black, the black / grey...


Items needing paint:

frame
wheels
all plastics
mufflers
gas tank
swing arm
forks

So, I spent a few hours dismantling my donor bike, and doing inventory. The donor bike will be used for engine, wiring harness, cooling system.
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Old March 12th, 2016, 07:07 PM   #34
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Ghostt, I don't understand your reply?
Send @ducatiman a PM he carries carburetor parts, be a lot cheaper.
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Old March 12th, 2016, 07:08 PM   #35
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I'm partial to orange myself, and look into satin black instead of flat.

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Old March 12th, 2016, 07:34 PM   #36
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On another note, when I use rattle can I use Krylon Fusion
http://www.krylon.com/products/fusion-for-plastic/
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Old March 14th, 2016, 05:58 AM   #37
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Thanks for the input Ghostt!

I have 2 other ideas for the blue / dark grey combo...

Ultra Cover 2x Gloss Spray - Gloss Navy Blue
Rust-Oleum 248930 Automotive High Performance Wheel Spray Paint, Graphite

If that doesn't work, Plastidip!
Plasti Dip - Flex Blue 11oz
PLASTI DIP GUNMETAL GRAY

Except for the gloss navy blue, I cannot find any of the other colors locally. It's too cold to paint today, anyway. I have so many plastic parts to repair and prep, so that is on tap for today.
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Old March 14th, 2016, 06:07 AM   #38
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The best deal that I can find this week is Jet.com $126.28 shipped, with a first time buyer 15% discount. I have decided to go with Pirelli Diablo O.E. Scooter Tire - 130/80 16 rear, and 100/80 16 front. I don't need these until repair and paint are completed, so I might wait and see where prices go over the next few weeks.
Tires ordered.

Old tires dismounted this weekend. Now to clean and paint.
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Old March 17th, 2016, 07:41 PM   #39
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Parts have been arriving. All Balls steering and wheel bearings, tires, brake pads, and wind deflector. Lots more ordered in the last few days. I want to put the bike back together right.
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Old March 17th, 2016, 07:45 PM   #40
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I completely disassembled the front caliper for inspection and cleaning. I have ordered a Galfer SS front brake hose, and need to replace the caliper seals.
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