October 27th, 2012, 04:32 PM | #1 |
ninjette.org guru
Name: Bob
Location: Chicago
Join Date: Sep 2012 Motorcycle(s): '06 Ninja 250, 2018 Honda GL1800B Posts: 315
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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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October 27th, 2012, 04:35 PM | #2 |
Ambrosia.
Name: Jaymie
Location: Oahu, Hawaii
Join Date: Aug 2011 Motorcycle(s): 1974 Honda CB550K0 W.I.P. Posts: A lot.
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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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October 27th, 2012, 05:22 PM | #3 |
CPT Falcon
Name: J.Emmett Turner
Location: Newnan, GA
Join Date: Apr 2009 Motorcycle(s): '08 CP Blue EX250J, '97 unpainted EX250F, 2nd '97 unpainted EX250F (no engine), '07 black EX250F Posts: A lot.
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You could bob the tail and half the seat.
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October 27th, 2012, 06:34 PM | #4 |
ninjette.org member
Name: Guy
Location: Arizona
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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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October 28th, 2012, 01:22 PM | #5 |
ninjette.org guru
Name: Bob
Location: Chicago
Join Date: Sep 2012 Motorcycle(s): '06 Ninja 250, 2018 Honda GL1800B Posts: 315
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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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October 28th, 2012, 01:31 PM | #6 |
ninjette.org certified postwhore
Name: Hansveer
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Looking good
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October 28th, 2012, 01:48 PM | #7 |
ninjette.org sage
Name: Andy
Location: Sheboygan, WI
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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.
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October 29th, 2012, 03:52 AM | #8 |
Present. Somewhat.
Name: Neel
Location: Bangalore, India
Join Date: Sep 2012 Motorcycle(s): 2012 KTM Duke 200, 2011 Ninja 250r, 2011 Ducati Monster 796, 2014 Kawasaki ZX10r Posts: 227
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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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October 29th, 2012, 08:54 AM | #9 |
ninjette.org guru
Name: Bob
Location: Chicago
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October 29th, 2012, 08:57 AM | #10 |
ninjette.org guru
Name: Bob
Location: Chicago
Join Date: Sep 2012 Motorcycle(s): '06 Ninja 250, 2018 Honda GL1800B Posts: 315
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October 29th, 2012, 08:59 AM | #11 |
ninjette.org guru
Name: Bob
Location: Chicago
Join Date: Sep 2012 Motorcycle(s): '06 Ninja 250, 2018 Honda GL1800B Posts: 315
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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.
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October 29th, 2012, 01:48 PM | #12 |
ninjette.org sage
Name: Luke
Location: Sevierville, TN
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wow very nice, I have an 06 as well, but yours looks much better than mine.
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October 29th, 2012, 01:51 PM | #13 | |
I told you bro
Name: Noor
Location: Austin, Texas
Join Date: Jun 2012 Motorcycle(s): 1996 Ninja 250r Posts: 680
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Quote:
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October 29th, 2012, 05:01 PM | #14 |
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All the fast ones switch to a ligher, sexier, full system
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October 29th, 2012, 07:10 PM | #15 |
Riding Ruby..
Name: Stephen
Location: SoCal
Join Date: Sep 2012 Motorcycle(s): 2014 Yamaha Bolt R-Spec, 2007 Ninja 250R Posts: 392
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this bike is beautiful
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October 29th, 2012, 07:30 PM | #16 |
ninjette.org member
Name: Sev
Location: Vancouver
Join Date: Jul 2011 Motorcycle(s): 09' 250r Thunder Blue Posts: 165
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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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October 29th, 2012, 07:53 PM | #17 |
CPT Falcon
Name: J.Emmett Turner
Location: Newnan, GA
Join Date: Apr 2009 Motorcycle(s): '08 CP Blue EX250J, '97 unpainted EX250F, 2nd '97 unpainted EX250F (no engine), '07 black EX250F Posts: A lot.
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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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October 29th, 2012, 08:00 PM | #18 |
Daily Ninjette rider
Name: Hernan
Location: Florida
Join Date: Mar 2011 Motorcycle(s): 2007 Ninja 250 Posts: A lot.
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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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October 29th, 2012, 09:12 PM | #19 |
ninjette.org member
Name: Zach
Location: Colorado Springs
Join Date: Mar 2011 Motorcycle(s): 96 Ninja 250EX , 87 CBR 1000, 86 TRX 260R, 86 KXT 250, 84 ATC 200X, 82 ATC 250R (w/CR480) Posts: 134
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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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October 30th, 2012, 04:32 AM | #20 |
ninjette.org guru
Name: Bob
Location: Chicago
Join Date: Sep 2012 Motorcycle(s): '06 Ninja 250, 2018 Honda GL1800B Posts: 315
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Thanks, everyone, for your appreciation and suggestions.
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October 30th, 2012, 05:05 AM | #21 |
CPT Falcon
Name: J.Emmett Turner
Location: Newnan, GA
Join Date: Apr 2009 Motorcycle(s): '08 CP Blue EX250J, '97 unpainted EX250F, 2nd '97 unpainted EX250F (no engine), '07 black EX250F Posts: A lot.
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Oh yeah: You could save a few more ounces by ditching the chrome frame caps. :P
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October 31st, 2012, 06:50 PM | #22 |
Riding Ruby..
Name: Stephen
Location: SoCal
Join Date: Sep 2012 Motorcycle(s): 2014 Yamaha Bolt R-Spec, 2007 Ninja 250R Posts: 392
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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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October 31st, 2012, 07:42 PM | #23 |
ninjette.org guru
Name: Bob
Location: Chicago
Join Date: Sep 2012 Motorcycle(s): '06 Ninja 250, 2018 Honda GL1800B Posts: 315
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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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October 31st, 2012, 07:48 PM | #24 |
Riding Ruby..
Name: Stephen
Location: SoCal
Join Date: Sep 2012 Motorcycle(s): 2014 Yamaha Bolt R-Spec, 2007 Ninja 250R Posts: 392
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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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November 5th, 2012, 08:47 AM | #25 |
ninjette.org guru
Name: Bob
Location: Chicago
Join Date: Sep 2012 Motorcycle(s): '06 Ninja 250, 2018 Honda GL1800B Posts: 315
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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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November 5th, 2012, 10:02 AM | #26 | |
ninjette.org sage
Name: Andy
Location: Sheboygan, WI
Join Date: Dec 2008 Motorcycle(s): 1988 Honda Hawk NT650, 1989 Honda Hawk NT650, 1997 GSXR750 Track Bike Posts: 890
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Quote:
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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November 5th, 2012, 10:09 AM | #27 |
ninjette.org guru
Name: Bob
Location: Chicago
Join Date: Sep 2012 Motorcycle(s): '06 Ninja 250, 2018 Honda GL1800B Posts: 315
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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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November 15th, 2012, 12:04 PM | #28 |
ninjette.org guru
Name: Bob
Location: Chicago
Join Date: Sep 2012 Motorcycle(s): '06 Ninja 250, 2018 Honda GL1800B Posts: 315
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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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November 17th, 2012, 06:37 PM | #30 |
ninjette.org member
Name: David
Location: woodbury
Join Date: Oct 2012 Motorcycle(s): lots Posts: 77
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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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March 25th, 2013, 05:48 PM | #31 |
ninjette.org member
Name: Jason
Location: Cabot, AR
Join Date: Apr 2012 Motorcycle(s): 2009 Ninja 250R Posts: 209
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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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March 26th, 2013, 08:50 PM | #32 |
ninjette.org certified postwhore
Name: Colin
Location: Bay Area
Join Date: Feb 2011 Motorcycle(s): '96 EX250 Posts: A lot.
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As a lane splitter, bar end mirrors suck. bar mounted would be better.
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March 27th, 2013, 06:35 AM | #33 | |
ninjette.org guru
Name: Bob
Location: Chicago
Join Date: Sep 2012 Motorcycle(s): '06 Ninja 250, 2018 Honda GL1800B Posts: 315
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Quote:
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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March 27th, 2013, 07:31 AM | #34 |
ninjette.org member
Name: J
Location: Dallas
Join Date: Aug 2012 Motorcycle(s): Ninja 250R '07 Posts: 81
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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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March 27th, 2013, 08:41 AM | #35 | |
ninjette.org guru
Name: Bob
Location: Chicago
Join Date: Sep 2012 Motorcycle(s): '06 Ninja 250, 2018 Honda GL1800B Posts: 315
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Quote:
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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March 27th, 2013, 01:38 PM | #36 |
ninjette.org member
Name: david
Location: house
Join Date: Apr 2011 Motorcycle(s): 1999 ex 250 Posts: 52
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nice
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March 27th, 2013, 01:51 PM | #37 |
ninjette.org member
Name: Jason
Location: Cabot, AR
Join Date: Apr 2012 Motorcycle(s): 2009 Ninja 250R Posts: 209
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At 17, I hope she's not splitting lanes. just saying
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March 27th, 2013, 03:31 PM | #38 |
ninjette.org certified postwhore
Name: Colin
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FYI it's not illegal in CA.
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March 27th, 2013, 04:41 PM | #39 |
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March 27th, 2013, 04:45 PM | #40 |
ninjette.org certified postwhore
Name: Colin
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