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Old October 27th, 2012, 04:32 PM   #1
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Lightening her up, part II

I spent Saturday tearing apart the rear end of the bike. Removed the bodywork, relocated the regulator/rectifier and ECU, painted the coolant tank and trimmed off some tabs and about 2" at the end of the frame, as well as part of the inner fender, then fabbed a taillight mount and turn signal mounts, and here we are:






I still have to clean up the underside of the seat, probably with an aluminum plate, and trim the front fender a little.

Here's how I trimmed the rear fender, so we could retain the original tool tray and seat latch springs, and protect the battery and seat from road spray:


Total weight savings: 27 lbs!

Later, I also trimmed the front fender for a more traditional profile:

Last futzed with by Chicagobob; November 13th, 2012 at 10:01 AM.
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Old October 27th, 2012, 04:35 PM   #2
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If you really want to lose some weight, go for a 2-1 exhaust. Also lightening it means nothing if you removed any sort of aerodynamics.
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Old October 27th, 2012, 05:22 PM   #3
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You could bob the tail and half the seat.
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Old October 27th, 2012, 06:34 PM   #4
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Quote:
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If you really want to lose some weight, go for a 2-1 exhaust. Also lightening it means nothing if you removed any sort of aerodynamics.
I don't think he was lightening to increase power; I thought it was to make it easier for his daughter to handle at low speeds
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Old October 28th, 2012, 01:22 PM   #5
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Here's where I mounted the rectifier and ignition modules (you can just see the ignition module peeking out from under the tank, where it's held in place with servo tape and foam):


And here's how I tidied up the undeside of the seat - a piece of sheet aluminum painted black:
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Old October 28th, 2012, 01:31 PM   #6
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Old October 28th, 2012, 01:48 PM   #7
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Quote:
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Here's where I mounted the rectifier and ignition modules (you can just see the ignition module peeking out from under the tank, where it's held in place with servo tape and foam):
I would have left a small section near the coolant tank marks clear in order to be able to see the level without having to open the cap at all.
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Old October 29th, 2012, 03:52 AM   #8
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Change the pipes, and if you're willing to put the effort in, fabricate a smaller tank. it really helps
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Old October 29th, 2012, 08:54 AM   #9
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I would have left a small section near the coolant tank marks clear in order to be able to see the level without having to open the cap at all.
Did - on the front side of the tank - not visible in the photo.
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Old October 29th, 2012, 08:57 AM   #10
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You could bob the tail and half the seat.
Well, I already bobbed it 2". It wouldn't look good if I cut off more, unless I was able to bend and re-weld the lower brace tubes, and that would also require different pipe support brackets - too much work.
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Old October 29th, 2012, 08:59 AM   #11
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If you really want to lose some weight, go for a 2-1 exhaust. Also lightening it means nothing if you removed any sort of aerodynamics.
I didn't want to delve into exhaust and intake mods, because this is a LOW budget build - the bike cost $1,500, I had the headlight and signals, the taillight was $20, the Trail Tech gauge was $95 used, and I hope to sell some of the removed parts to get a little back from that.
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Old October 29th, 2012, 01:48 PM   #12
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wow very nice, I have an 06 as well, but yours looks much better than mine.
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Old October 29th, 2012, 01:51 PM   #13
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Quote:
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I didn't want to delve into exhaust and intake mods, because this is a LOW budget build - the bike cost $1,500, I had the headlight and signals, the taillight was $20, the Trail Tech gauge was $95 used, and I hope to sell some of the removed parts to get a little back from that.
It's OK, all the cool ninja 250s stick with dual exhaust anyways
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Old October 29th, 2012, 05:01 PM   #14
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Old October 29th, 2012, 07:10 PM   #15
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this bike is beautiful
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Old October 29th, 2012, 07:30 PM   #16
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Very nice. If you can afford it i would retrofit a RD 250 or similar tank, love the squarish look, and maybe free up some space (relocate battery box etc) looks good tho. If i were to grab a pre gen this would be it! Dont know if you know it but Pick up a few copies of Practical Sporbikes if you can. lots of helpful tips and great for ideas. keep it up!
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Old October 29th, 2012, 07:53 PM   #17
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You could ditch that solid sprocket cover or switch it out with one from a J-series (less solid).

I always though the solid glossy pregen one was ugly anyway.
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Old October 29th, 2012, 08:00 PM   #18
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........Total weight savings: 27 lbs!
Impressive save !

However, I liked Part I much better than Part II.

You could save much more switching to skinnier tires.
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Old October 29th, 2012, 09:12 PM   #19
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Looking good I considered doing my girlfriends bike the same way but she likes the look with the farings on .... If you decide to get rid of parts I am looking for a set of th passenger pegs I have the bracket just need pegs and hardware
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Old October 30th, 2012, 04:32 AM   #20
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Thanks, everyone, for your appreciation and suggestions.
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Old October 30th, 2012, 05:05 AM   #21
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Oh yeah: You could save a few more ounces by ditching the chrome frame caps. :P
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Old October 31st, 2012, 06:50 PM   #22
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did you need to weld anything? like, would one with no-to-minimal metal working experience be able to do this aswell?
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Old October 31st, 2012, 07:42 PM   #23
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did you need to weld anything? like, would one with no-to-minimal metal working experience be able to do this aswell?
I didn't do any welding, but used a sawzall to de-tab the frame and bent some sheet metal for the taillight mount - pretty basic stuff. I used 1" plastic hole plugs from Ace Hardware to plug the ends of the frame tubes, and brush-on Rustoleum gloss black paint to cover any bare metal exposed by my cutting and grinding.

Last futzed with by Chicagobob; November 1st, 2012 at 05:28 AM.
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Old October 31st, 2012, 07:48 PM   #24
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nice, i really dig this, and when i get my bike i'm probably gunna use this as a model, so i wanted to know what i was in for.
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Old November 5th, 2012, 08:47 AM   #25
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New instrument panel

I got a good deal on a Trail Tech indicator light panel for the Vapor Speedo/Tach. Since the Kawasaki indicator light sockets plug right in, I was able to simply use the stock wiring harness, sockets and bulbs, for a five-minute installation. Here it is:



It's mounted by sliding the bracket under the steering lock housing cover, then drilling it and securing it with two small stainless steel bolts (from a computer chassis, but not yet installed in this photo). Then, after looking at the result, I realized I could have mounted it directly to the headlight bucket with 1" spacers, and run the wires through a hole.


Last futzed with by Chicagobob; November 13th, 2012 at 09:24 AM.
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Old November 5th, 2012, 10:02 AM   #26
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I got a good deal on a Trail Tech indicator light panel for the Vapor Speedo/Tach. Since the Kawasaki indicator light sockets plug right in, I was able to simply use the stock wiring harness, sockets and bulbs, for a five-minute installation. Here it is:

Looks good. I've got the same setup on one of my Hawks. I prefer it much more to the Koso I have on my first Hawk.

I made a plate out of some spare Carbon Fiber for my gauge and mounted it to the tapped holes for Ignition cover.


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Old November 5th, 2012, 10:09 AM   #27
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Nice, but the pregen doesn't have such holes, unless you want to drill out the ignition switch security bolts.
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Old November 15th, 2012, 12:04 PM   #28
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Pics of the final product (as of today, anyhow)

I had the chance to take a few photos of the whole bike after trimming the fender (and a little more off the side covers). Bike is also running well, and my daughter used it to pass her DMV test.





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Old November 15th, 2012, 03:28 PM   #29
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love it

for $60 you can switch to a lipo battery and save about 8 lbs
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Old November 17th, 2012, 06:37 PM   #30
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I think it would look good to cut something like a tank pad material and glue to the tank in the whole recessed area where the faring covered it. Maybe you could be creative and incorporate some pouches or something there functional. I very much like your ideas and what this is looking like.
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Old March 25th, 2013, 05:48 PM   #31
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Very nice. Maybe lose some more weight with clipons and bar-end mirrors. Makes me wish I had a pre-gen again.
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Old March 26th, 2013, 08:50 PM   #32
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As a lane splitter, bar end mirrors suck. bar mounted would be better.
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Old March 27th, 2013, 06:35 AM   #33
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Very nice. Maybe lose some more weight with clipons and bar-end mirrors. Makes me wish I had a pre-gen again.
You are right, and we wanted to go with lightweight clip-ons and bar-end mirrors, largely because the stock handlebars are heavy and because we wanted to lower the front end an inch or so to reduce fork flex a little.

However, we designed this bike for a 17-year-old new rider, so we thought the stock bars with conventional mirrors would be better at this point.

Maybe this summer . . .

We recently installed a new chain and 15/45 sprockets, and shimmed the cush drive, and we have a SS front brake line and new pads on the shelf, ready to go on when there's a little time.

Anyhow, here's the new rear end after we detabbed it a little more). I've since painted the exhaust brackets flat black:


And a before/after shot:


Later, after adding clip-ons:

Last futzed with by Chicagobob; April 8th, 2013 at 06:58 AM.
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Old March 27th, 2013, 07:31 AM   #34
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First let me say that you've done an amazing job and I love the bike. I am curious how it rides with all the modifications compared to stock.
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Old March 27th, 2013, 08:41 AM   #35
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First let me say that you've done an amazing job and I love the bike. I am curious how it rides with all the modifications compared to stock.
The suspension seems a little stiffer due to the reduced weight, and there's no wind protection (unless a big tank bag is being used), but that's what we're used to from classic bikes. There's no reason we couldn't install a windshield or flyscreen.

The bike now has a much lighter feel, changes direction more easily, and accelerates and brakes slightly better. You don't even notice a lag from the 15T front sprocket.

Significantly, it is much less top-heavy than it was, which made the DMV test easier.

I'd say it's a significant improvement over the stock configuration.
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Old March 27th, 2013, 01:38 PM   #36
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nice
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Old March 27th, 2013, 01:51 PM   #37
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As a lane splitter, bar end mirrors suck. bar mounted would be better.
At 17, I hope she's not splitting lanes. just saying
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Old March 27th, 2013, 03:31 PM   #38
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At 17, I hope she's not splitting lanes. just saying
FYI it's not illegal in CA.
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Old March 27th, 2013, 04:41 PM   #39
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FYI it's not illegal in CA.
But still a potentially terrifying idea to a parent.
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Old March 27th, 2013, 04:45 PM   #40
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But still a potentially terrifying idea to a parent.
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