Doing a little work on my first bike

[ARD7.62]

Hi guys and gals,

I decided since my rear tire was going bald that I would park it and do a little work. Tires led to carbs, carbs led to rear fender, rear fender led to fork seals. It's funny how that works.

The bike is a 2005 ninja 250 I got for $1100 with 1300miles on it. Before i parked it I am at almost 3k. No real problems except leaking fork seals, stock tires, and a slightly rusty tank that screwed up my carbs.

I have to cut the damn dust seals off because they are fused with the fork mount. Any tips? I found a write up on disassembly and maintenance on here I'm going to follow.

I sent my carbs to Ducatiman and got them back pretty quick considering I sent them during the new years weekend. I'm hoping he didn't work on them until after the holiday. I going to give him a shout out after I get the bike running again.

Anyway here are some pics.

Here it is before



The crack in my side fairing is driving me nuts.




And here it is torn down

[ARD7.62]

I also got the light smoked rear turn signal covers. I swear Kawasaki wanted me to do this. the sockets i got with the lenses suck. They wouldn't let the bulbs turn and lock. Luckily I replaced them with LEDs and was able to rig them by drilling holes into the socket and using a zip tie to keep the lights in place. Don't judge me.

I also cut the rear fender flush with the rear fairing. I used the old inspection sticker plate to mount the plate below the tail light. Again, I swear Kawasaki is guiding me because there is a knockout on the bottom of the taillight to let light through onto the plate. I need to find some clear plastic to make it water resistant again.

I think it came out pretty good. I used a hacksaw blade to cut the fender and you can tell if you look real close, but it's not really noticeable.

No more words, just pics.

[csmith12]

Nice!

[adouglas]

If rust in the tank caused your carb issue, then what are you doing about the tank?

Can't help you on the fork seals... never had to tackle that particular project myself.

[ARD7.62]

Thanks!

Ducatiman helped me there too. He recommended POR15 and after looking around I decided to go with that. I'll be doing that next week if I'm working in town.

[spent_too_much]

While your at it, may I suggest a "new" rear shock, and front fork upgrade? Used Newgen 250 / 300 front fork springs, and a Newgen 250 / 300 rear shock. No modifications required, and what a difference!

[Triple Jim]

I would consider Caswell's Phenol Novolac epoxy as a tank coating, if you need one.

[ARD7.62]

Originally Posted by spent_too_much

While your at it, may I suggest a "new" rear shock, and front fork upgrade? Used Newgen 250 / 300 front fork springs, and a Newgen 250 / 300 rear shock. No modifications required, and what a difference!

I see why you chose that username. Haha. I'll look into it. I'm on a budget saving up for a house. Maybe next winter.

Originally Posted by Triple Jim

I would consider Caswell's Phenol Novolac epoxy as a tank coating, if you need one.

I got the kit from POR15 for motorcycle gas tanks. I'll give that a look though for next time though. Thanks.

[spent_too_much]

I understand. You can snag a rear shock for around $35 USD - shipped...

[ARD7.62]

When you say newgen, is that 2013+ or 2008+? I didn't realize they'd be that cheap.

[spent_too_much]

Newgen 250 = 2008-2012
300 = 2013 +

Or there abouts...

[ARD7.62]

Ok thanks!

[Ghostt]

Welcome, and it warms my heart to see a PreGen fixed.

I won't worry about the dust seals, assuming you got new ones with the seals, just get them out.

If your interested in low cost modifications, take a look at my blog.

As far as the suspension goes, it's the upgrade I personally recommend, as it's the best bang for the buck. The important thing is to match it to you weight.

With SERENITY, I with with a ZX600 rear shock, and I cut and shimmed a pair of spare EX500 fork springs, also with with 15w fork oil.

http://faq.ninja250.org/wiki/Ninja250_Howto

The above is probably the best Wiki for the 250, in case you haven't found it yet. A lot of great information there, some is dated, but for the most part it's up to date.

[ARD7.62]

Originally Posted by Ghostt

Welcome, and it warms my heart to see a PreGen fixed.

I won't worry about the dust seals, assuming you got new ones with the seals, just get them out.

If your interested in low cost modifications, take a look at my blog.

As far as the suspension goes, it's the upgrade I personally recommend, as it's the best bang for the buck. The important thing is to match it to you weight.

With SERENITY, I with with a ZX600 rear shock, and I cut and shimmed a pair of spare EX500 fork springs, also with with 15w fork oil.

http://faq.ninja250.org/wiki/Ninja250_Howto

The above is probably the best Wiki for the 250, in case you haven't found it yet. A lot of great information there, some is dated, but for the most part it's up to date.

Thanks.

I have been looking through your stuff and the wiki quite a bit. I've found the proper setup for my weight for the suspension, I just don't have the extra cash after doing things that are major issues. I will get that done after my wife and I get this house.

It's funny because I was just going to ride this until the spring putting the least amount of money into it as I could, but even when I get the bigger bike I am definitely keeping this one.

[Ghostt]

Originally Posted by ARD7.62

Thanks.

I have been looking through your stuff and the wiki quite a bit. I've found the proper setup for my weight for the suspension, I just don't have the extra cash after doing things that are major issues. I will get that done after my wife and I get this house.

It's funny because I was just going to ride this until the spring putting the least amount of money into it as I could, but even when I get the bigger bike I am definitely keeping this one.

Don't be in a hurry it upgrade to a bigger bike, unless you and the wife plan some 2 up riding, the 250 is bit small for that I have found.

I must say the owning both the 250, and 500 they are amazing bikes, and very capable of amazing performance, handling, easy and inexpensive to maintain, compared to bigger bikes.


Either way you in for some fun times.


Now it's time for my standard greeting,

Welcome, here are just a few things to think about,

1.Get trained and licensed MSF Courses

2.ALWAYS Wear protective gear -- ATGATT All The Gear, All The Time -- including a helmet manufactured to the standards set by a government agency.

3.ALWAYS Ride unimpaired by alcohol or other drugs

4.ALWAYS Ride within your own skill limits and road conditions.

5.Be a lifelong learner by taking refresher rider courses, and advanced rider course A.R.C.

https://www.ninjette.org/forums/showthread.php?t=218237

https://www.ninjette.org/forums/show...8&postcount=26

A.T.G.A.T.T. so I may ride another day.

Link to original page on YouTube.

Link to original page on YouTube.
Notice how the right shoulder seemed to tear?

[ARD7.62]

Originally Posted by Ghostt

Don't be in a hurry it upgrade to a bigger bike, unless you and the wife plan some 2 up riding, the 250 is bit small for that I have found.

I must say the owning both the 250, and 500 they are amazing bikes, and very capable of amazing performance, handling, easy and inexpensive to maintain, compared to bigger bikes.


Either way you in for some fun times.


Now it's time for my standard greeting,

Welcome, here are just a few things to think about,

I'm not in a hurry, though I may get a 1000cc+ cruiser next and get a bigger sport bike later. I've done some small stretches on the 250 and the only things I wish it had was storage and a leg room.

I mentioned you in my welcome post but I didn't "mention" you haha.

Originally Posted by ARD7.62

And I'll add, for Ghostt, that I have an Arai Signet Q helmet, Joe Rocket textile jacket and pants, and Sidi roarr boots. I also got my BRC completed and M endorsement.

[Triple Jim]

I don't think anyone mentioned an inline fuel filter, but I'm a big fan of those. A little rust or debris in the tank will be caught be a pleated paper filter, and if the problem isn't severe it will eventually go away.

[ARD7.62]

Originally Posted by Triple Jim

I don't think anyone mentioned an inline fuel filter, but I'm a big fan of those. A little rust or debris in the tank will be caught be a pleated paper filter, and if the problem isn't severe it will eventually go away.

it had a fuel filter on it, but it wasn't the paper type. It's on my list when I buy a new petcock assembly.

Thanks!

[JohnnyBravo]

Looks like good work so far

[Triple Jim]

Originally Posted by ARD7.62

it had a fuel filter on it, but it wasn't the paper type.

I recently had the sintered metal type filter let a chunk though that clogged the main jet of my DT100's carb, so I figure those filters are about useless.

[ARD7.62]

I finished the tank restore. Looks pretty good and only got a little on the paint. I got a lot of rust out when I drained the tank and noticed my petcock did not have filter screens. they weren't anywhere so they either disintegrated or weren't there at all.

While I was trying to get the dust boots off the forks, I scratched the crap out of one. I have to sand it down and clean it up or I'm just going to have the same problem. At least I learned from this so it shouldn't happen again.

I got my fork seals and dust boots from all balls, but the top part of the dust boot wasn't included. I have the part that attaches to the fork itself, but not the part that hugs the chrome part of the fork. Is there a special name for this or do I need to contact all balls and get them to give me everything?

I'm only waiting on a new petcock, paper filter, and finish my fork seals and I'll be back on the road.