May 31st, 2011, 01:05 PM | #1 |
Accesories Guru
Name: Dave
Location: Centreville, VA
Join Date: May 2011 Motorcycle(s): '99 EX250(Cafe/fighter project) Posts: 537
|
99 Ex 250 project Cafe/streetfighter, The build thread.
Well, I decided t man up and post a build thread. I bought it for basically nothing from a friend and have added parts big as small over the past 2 years. basically it was a frame with a title and a bunch of parts, had to buy an engine in 2 pieces from 2 sellers which together makes up at a nicely 1700 mile engine.
Is taken a lot of blood sweat and tears but is finally shaping up into a nice looking machine. How it all started Some progress: Assembled the front fork and mounted the wheels in place(place holding until I get some new parts). and what I want it to look like: . I'm currently doing a top end rebuild and carb cleaning, so far is a roller and finally got around to installing an ALL BALLS stem bearing upgrade set. hope to be done soon and be riding by either the season's end or next season. I did some work yesterday and finally installed the radiator(after extensive cleaning) my new engine mounts(ACE is my new favorite place , loads of metric bolts and cheap) and the center stand, I can finally work on it with ease. here is she as she stands: Also I worked on sanding my tank and was planning to leave it bare metal, but my Dad had a goofy moment and this happened: He felt so bad for the rest of the day, but I told him not to worry about it. He then proceeded to go behind my back and call a mutual friend who does body work and offered to pay for it. I love him so much. Well, here is the beginning, feel free to ask questions, comment, share , discuss, send donations to me , etc. Hope you guys like it and stick around to see the results. |
|
May 31st, 2011, 01:19 PM | #2 |
Ninjette Owner
Name: Rick
Location: Aiken County, SC
Join Date: Jun 2010 Motorcycle(s): 2009 Ninja 250R SE, a puddle of Ninja ZX6 Posts: 520
|
It is starting to look like a bike already. Can't wait to see how it looks in the end.
__________________________________________________
|
|
May 31st, 2011, 01:45 PM | #3 |
Join Date: Nov 2008 Posts: Too much.
|
|
|
May 31st, 2011, 02:30 PM | #4 |
Wartown, USA
Name: Bryan
Location: Warner Robins, GA
Join Date: Nov 2009 Motorcycle(s): 2009 Ninja 250R SE, 2007 Ninja 650R, and assorted other bikes Posts: A lot.
|
too
|
|
May 31st, 2011, 02:59 PM | #5 |
ninjette.org member
Name: Tony
Location: Surrey UK
Join Date: Aug 2010 Motorcycle(s): GPX250 + many others! Posts: 184
|
Looking forward to seeing this progress, good luck
|
|
May 31st, 2011, 03:42 PM | #6 |
ninjette.org certified postwhore
Name: Colin
Location: Bay Area
Join Date: Feb 2011 Motorcycle(s): '96 EX250 Posts: A lot.
|
That's funny. Looks just like my fighter build. Even has the same color tank and wheels. It will be cool to see how they turn out differently! I'm not posting a build thread until it's mechanically sound though.
If the tank is being repaired, you should have them shave the fairing mounts at the same time. What are your plans for gauges and rear cowl? |
|
May 31st, 2011, 03:42 PM | #7 |
Join Date: Nov 2008 Posts: Too much.
|
|
|
May 31st, 2011, 04:31 PM | #8 | |
Accesories Guru
Name: Dave
Location: Centreville, VA
Join Date: May 2011 Motorcycle(s): '99 EX250(Cafe/fighter project) Posts: 537
|
Quote:
PS: the fairing mounts are definitely getting shaved and smoothed out. |
|
|
May 31st, 2011, 05:38 PM | #9 |
ninjette.org guru
Name: Bill
Location: NC
Join Date: Apr 2011 Motorcycle(s): Ninja 250 Posts: 282
|
Looking forward to seeing your build!!!!
|
|
May 31st, 2011, 09:03 PM | #10 |
Accesories Guru
Name: Dave
Location: Centreville, VA
Join Date: May 2011 Motorcycle(s): '99 EX250(Cafe/fighter project) Posts: 537
|
Drew this tonight because I was bored and infatuated with the work of Radical Ducati( a shop from Spain)
Is a more definite concept of what I want. Will upload a better one once Fb comes back on. |
|
May 31st, 2011, 11:27 PM | #11 |
ninjette.org certified postwhore
Name: Colin
Location: Bay Area
Join Date: Feb 2011 Motorcycle(s): '96 EX250 Posts: A lot.
|
Are you going to chop the lower frame and bend it upwards at the swingarm mount?
Last futzed with by CynicalC; June 1st, 2011 at 04:45 PM. |
|
May 31st, 2011, 11:59 PM | #12 |
ninjette.org member
Name: Tony
Location: Surrey UK
Join Date: Aug 2010 Motorcycle(s): GPX250 + many others! Posts: 184
|
I've seen quite a few cafe racer seat cowls recently that were fabricated from old gas tanks, usually a slim model from a '70's or '80's Jap bike.
|
|
June 1st, 2011, 07:39 AM | #13 | |
Accesories Guru
Name: Dave
Location: Centreville, VA
Join Date: May 2011 Motorcycle(s): '99 EX250(Cafe/fighter project) Posts: 537
|
Quote:
Wow, that is actually interesting, I will be researching it. |
|
|
June 6th, 2011, 09:04 AM | #14 |
ninjette.org newbie
Name: ricky
Location: baytown tx
Join Date: May 2010 Motorcycle(s): ninja 250 Posts: 8
|
wow.....keeping eyes peeled
|
|
June 6th, 2011, 09:09 AM | #15 |
Always.
Name: Alex
Location: Calgary, AB
Join Date: Mar 2011 Motorcycle(s): '08 Ninja 250, '05 GSX-R600 Posts: A lot.
|
Well this bike is honestly going to be yours and truly custom =p
Goodluck! Looking good already |
|
June 6th, 2011, 07:47 PM | #16 |
Accesories Guru
Name: Dave
Location: Centreville, VA
Join Date: May 2011 Motorcycle(s): '99 EX250(Cafe/fighter project) Posts: 537
|
Thanks guys, anyone know if the 2 wheel levers would fit this bike? also wondering about the current gen wheels fitting this ninja.
|
|
June 27th, 2011, 11:36 AM | #17 |
Accesories Guru
Name: Dave
Location: Centreville, VA
Join Date: May 2011 Motorcycle(s): '99 EX250(Cafe/fighter project) Posts: 537
|
Bad news everyone, I was prepping my engine for that top half rebuild I intended to have done, and I found this:
I think this throws away my budget, I am so frustrated and don't know what to do about it. Thoughts? I will truly appreciate them. Last futzed with by cerberusrex25; August 3rd, 2011 at 12:06 PM. |
|
June 27th, 2011, 11:42 AM | #18 |
ninjette.org guru
Name: Jesse
Location: Ann arbor mi
Join Date: Mar 2011 Motorcycle(s): 2007 ninja 250r Posts: 374
|
If you are not capable of doing the lower end your self I would go buy a running motor should be around 700
|
|
June 27th, 2011, 12:48 PM | #19 |
ninjette.org member
Name: Tony
Location: Surrey UK
Join Date: Aug 2010 Motorcycle(s): GPX250 + many others! Posts: 184
|
My opinion, (bearing in mind I'm new to these bikes, and only just rebuilt the top end on mine), is that mainly rust I can see in there? If it is just the head gasket that has leaked water into the cylinder, don't panic quite yet. Lift the barrel, if that piston is stuck in the bore, pore some paraffin or diesel down the bore and leave it a few days to free it. Be careful that you don't drop too much crud and stuff down into the crankcase when you lift it. Always a good idea to push some rags into the opening as you lift the barrel.
It's possible that the bore can be honed by a local machine shop, or even using a hone attachment yourself. Get some new rings, and clean the piston up. You must get the head and barrel checked for flatness on the mating surface too, it may be that a warp caused the problem in the first place. Of course, I'm just going by what I can see in the pictures, is the piston actually damaged ? Good luck, and like I said, don't always expect the worse, (if I had with mine, it would be in the canal by now ). |
|
June 27th, 2011, 12:51 PM | #20 |
ninjette.org member
Name: Tony
Location: Surrey UK
Join Date: Aug 2010 Motorcycle(s): GPX250 + many others! Posts: 184
|
Taking another look at the pictures, I guess the motor may have been left out in the open with no spark plug in the hole, the resulting rusty mess can often be less trouble than at first it seems.
|
|
June 27th, 2011, 10:26 PM | #21 |
Accesories Guru
Name: Dave
Location: Centreville, VA
Join Date: May 2011 Motorcycle(s): '99 EX250(Cafe/fighter project) Posts: 537
|
Thanks Tony, I think you might be correct. The piston seems to be a little cruddy but generally OK, I don't really see any major damage aside from the rust. if it helps it had a bunch of solidified crud in there too, I think your theory about the no spark might be quite accurate. I wont get discouraged and clean it up and buy some rings and take it to my mechanic.
|
|
July 8th, 2011, 10:02 AM | #22 |
Accesories Guru
Name: Dave
Location: Centreville, VA
Join Date: May 2011 Motorcycle(s): '99 EX250(Cafe/fighter project) Posts: 537
|
Got this little treat today thanks to CynicalC:
they fit like a glove, this is so I can get her street legal and running. The engine drama continues. |
|
July 8th, 2011, 06:13 PM | #23 |
Accesories Guru
Name: Dave
Location: Centreville, VA
Join Date: May 2011 Motorcycle(s): '99 EX250(Cafe/fighter project) Posts: 537
|
All mounted up just to see how it would look, now I need to fix that damn engine. Last futzed with by cerberusrex25; August 3rd, 2011 at 12:08 PM. |
|
July 11th, 2011, 08:53 PM | #24 |
Accesories Guru
Name: Dave
Location: Centreville, VA
Join Date: May 2011 Motorcycle(s): '99 EX250(Cafe/fighter project) Posts: 537
|
worked on my engine today, here is the result after 2 hours of wiping and brushing it with gasoline
Also piston was not stuck, just gunky. Outlook is looking better. Last futzed with by cerberusrex25; August 3rd, 2011 at 12:07 PM. |
|
July 11th, 2011, 08:58 PM | #25 |
Accesories Guru
Name: Dave
Location: Centreville, VA
Join Date: May 2011 Motorcycle(s): '99 EX250(Cafe/fighter project) Posts: 537
|
Yeah, I paid 300 for the bike, and had invested another 400/500 on it. I tried the whole gunk be gone think and it seems it was only surface stuff, will inquire on getting it bored 1 micron or so just so is all smooth and stuff.
|
|
July 12th, 2011, 09:57 AM | #26 |
Accesories Guru
Name: Dave
Location: Centreville, VA
Join Date: May 2011 Motorcycle(s): '99 EX250(Cafe/fighter project) Posts: 537
|
Someone suggested I use a dremmel and a brass brush, is this safe? I dont want to mess up the chamber and have to end up changing the sleeve.
|
|
July 12th, 2011, 10:20 AM | #27 |
ninjette.org guru
Name: Jesse
Location: Ann arbor mi
Join Date: Mar 2011 Motorcycle(s): 2007 ninja 250r Posts: 374
|
Use a diamond hone
|
|
July 12th, 2011, 01:06 PM | #28 |
Accesories Guru
Name: Dave
Location: Centreville, VA
Join Date: May 2011 Motorcycle(s): '99 EX250(Cafe/fighter project) Posts: 537
|
I would, if I had the skill and knowledge to bore it, I take it a brass brush will be a safe way to get rid of the rest of the loose grime that is still there.
|
|
July 12th, 2011, 03:24 PM | #29 |
ninjette.org member
Name: Tony
Location: Surrey UK
Join Date: Aug 2010 Motorcycle(s): GPX250 + many others! Posts: 184
|
It would be, though you look like you got most already ...
|
|
July 12th, 2011, 03:45 PM | #30 |
Accesories Guru
Name: Dave
Location: Centreville, VA
Join Date: May 2011 Motorcycle(s): '99 EX250(Cafe/fighter project) Posts: 537
|
I did, is just it has a few left over pieces of crap in there. My father keeps telling me not to worry since those are just carbon deposits and I might end up messing it up.
|
|
July 12th, 2011, 03:47 PM | #31 |
ninjette.org member
Name: Tony
Location: Surrey UK
Join Date: Aug 2010 Motorcycle(s): GPX250 + many others! Posts: 184
|
I'd say he's right, looks fine to me, told you not to worry too much the other week ...............
|
|
July 12th, 2011, 03:51 PM | #32 |
Accesories Guru
Name: Dave
Location: Centreville, VA
Join Date: May 2011 Motorcycle(s): '99 EX250(Cafe/fighter project) Posts: 537
|
True that, I guess I'm such a Worry Warren when it comes to the unknown. I believe this will be a green light on the rebuilt? I want to make sure before taking it to the mechanic this Friday.
|
|
July 12th, 2011, 09:59 PM | #33 |
ninjette.org certified postwhore
Name: Colin
Location: Bay Area
Join Date: Feb 2011 Motorcycle(s): '96 EX250 Posts: A lot.
|
Looks good! Glad those parts worked out. I got the check from the post office yesterday. I feel bad cashing it. It looks so antique. I bet they had to dig it out of a warehouse basement somewhere hah.
|
|
July 12th, 2011, 10:02 PM | #34 |
Accesories Guru
Name: Dave
Location: Centreville, VA
Join Date: May 2011 Motorcycle(s): '99 EX250(Cafe/fighter project) Posts: 537
|
HAHAH, jolly good, the smell of olde money, BRILLIANT!!!, glad to hear you got paid man. Pleasure doing business with you.
|
|
July 23rd, 2011, 04:54 PM | #35 |
Accesories Guru
Name: Dave
Location: Centreville, VA
Join Date: May 2011 Motorcycle(s): '99 EX250(Cafe/fighter project) Posts: 537
|
So thanks to Bosgarage57 and CZroe I finally tracked down and integrated tail light kit. bought it today and is finally in transit. As the day grew hotter and my idle mind kept running I decided to Do Work and finally chopped that ugly fender.
Here is the result: And the carnage that preceded it: Last futzed with by cerberusrex25; August 3rd, 2011 at 12:10 PM. |
|
July 23rd, 2011, 05:21 PM | #36 |
wat
Name: wat
Location: tustin/long beach
Join Date: Sep 2009 Motorcycle(s): wat Posts: Too much.
Blog Entries: 5
MOTM - Oct '12, Feb '14
|
is that the stock position for the regulator/rectifier? build is looking good... did you resolve your piston/cylinder issues?
__________________________________________________
|
|
July 23rd, 2011, 05:25 PM | #37 |
Accesories Guru
Name: Dave
Location: Centreville, VA
Join Date: May 2011 Motorcycle(s): '99 EX250(Cafe/fighter project) Posts: 537
|
Not sure about the rectifier, I took it off to wash that plastic pan is attached to, so I might've put it on backwards. As for the piston, yes it turns out it was not stuck and it was all surface grime that came from the upper side due to it not having a sparkplug in it and left outside by the previous owner, I went at it with a brass brush and some 600 grit sandpaper with oil and is good to go. will be taking it to the mechanic the week after next one.
|
|
July 24th, 2011, 01:11 PM | #38 |
ninjette.org certified postwhore
Name: Colin
Location: Bay Area
Join Date: Feb 2011 Motorcycle(s): '96 EX250 Posts: A lot.
|
Hey I just realized I still have those 4 little tie-down clips that go with the tail piece. Do you want me to send them to you?
|
|
July 24th, 2011, 04:19 PM | #39 |
Accesories Guru
Name: Dave
Location: Centreville, VA
Join Date: May 2011 Motorcycle(s): '99 EX250(Cafe/fighter project) Posts: 537
|
HAHAH, no worries dude, I had some that came with the bike. Thanks for worrying though.
|
|
July 25th, 2011, 11:14 AM | #40 | |
ninjette.org member
Name: Bob
Location: Centreville va
Join Date: Sep 2010 Motorcycle(s): 1991 EX500 , 2009 250r Posts: 130
|
Quote:
They have the shape you want and can be pretty cheap seeing as you can make due with a damaged one. There may be some other ones that work too. I'm in Centreville too btw, off Compton, if ya need a hand with anything And I'm the same Bob138 from customfighters Bob |
|
|
Similar Threads | ||||
Thread | Thread Starter | Forum | Replies | Last Post |
Ninja 250 racer build thread | bitaria | Ninjettes At Speed | 81 | December 8th, 2015 08:19 AM |
Spooph's 250 build thread | spooph | 2008 - 2012 Ninja 250R Tech Talk | 63 | November 24th, 2015 07:56 AM |
Rich's Cafe Build thread | extremez31 | 1986 - 2007 Ninja 250R Tech Talk | 43 | September 4th, 2015 05:31 PM |
Another 250 streetfighter build | cuong-nutz | 2008 - 2012 Ninja 250R Farkles | 19 | April 11th, 2015 08:58 PM |
My 07 250 cafe racer build | elephantman78 | 1986 - 2007 Ninja 250R Farkles | 12 | December 25th, 2014 07:09 AM |
|
|