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Old August 14th, 2015, 06:03 AM   #1
cgborders
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Start of new Project- Budget Cafe Build

So its been a while since I've been on here. But I couldn't stay away from the draw of the little 250s. So now I'm back into the ninjette world. I have this problem that I can't leave anything stock, so my most recent project is going under the knife. Building a cafe racer (nothing original, I know, lot of these being built). I've built a few other cafes in the past but they've all been vintage bikes- CB750, KZ400, KZ550, KZ305 (still a work in progress).



I've wanted to build one out of a modern bike; a budget 250 sounds like great place to start.

Back-story: I picked up a pair of 2007 Ninja 250s. Both were low miles bike, and both parked in late 2008, no keys on either, not running, one had been laid down lightly.
After beginning to tear into them to see what I actually had I developed my plan- rebuild the nicer of the two and sell it to fund the second as a project. So new tires, forks rebuilt, tank sealed, fluids changed, plgs, carbs rebuilt, lots of elbow grease, etc the first was finished and sold.



Current Build:
Now its time to start the fun one- The cafe (still waiting on a name for this one)
Mechanics squared away: forks rebuilt, new tires, chain, bearing repacked, brakes flushed, coolant flush, plugs, filter, carbs cleaned/ jetted/ synced, etc. Test drive. then strip it back down to start modifications.

I'll get more pics as it moves along but here is very rough mock-up to get idea of where we are going.



On a side note- I'm selling all the extras off this build to fund it (I'll post in for sale section, I just don't have high enough post count yet).
Selling: seat (x2), all fairings (main and front fender cracked), tail light, grab bar, headlight, seat latch, helmet lock, mirrors
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Old August 14th, 2015, 06:51 AM   #2
csmith12
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Old August 14th, 2015, 06:56 AM   #3
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Lets see some of those KZs
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Old August 14th, 2015, 08:14 AM   #4
cgborders
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Quote:
Originally Posted by sharky nrk View Post
Lets see some of those KZs
Starting point: last ran in 1987


Finished:






Starting point: last ran in 1982 (its an '82 model- 26 miles on it! A tree fell on it and was deemed total loss but somehow stayed together)


Still a ways to go but alive and running (with single carb conversion)


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Old August 14th, 2015, 08:27 AM   #5
NGagne
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Same here
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Old September 7th, 2015, 04:19 PM   #6
cgborders
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Haven't made as much progress as I'd like (too many house projects and painting a buddies car); but I'm moving forward.

Frame modified for straighter backbone

Then started fabrication of new seat and frame (still very early/rough in pics)



And modifying side covers





And removing tanks indentations



Also installed LED round headlight and built the foam part of seat but no pics yet.

Next big hurdle is gauge cluster- I want to keep stock gauges since show accurate mileage (2k) but need different housing and mounts.
Still some more bodywork to do and get it ready for paint.

Also thinking about adding some different mufflers- I've used sportster take-off on other projects. They are cheap and flow well for this small a bike.
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Old September 7th, 2015, 07:29 PM   #7
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Same here
Me three.
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Old September 9th, 2015, 02:25 PM   #8
cgborders
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Seat finished. Still need some bodywork but basic lines are there.





and headlight
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Old September 9th, 2015, 03:32 PM   #9
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How did you fill in the front faring indentations in the tank?
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Old September 9th, 2015, 05:21 PM   #10
MAZ 80
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That's some serious bodywork. Well done.
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Old September 10th, 2015, 11:32 AM   #11
cgborders
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Quote:
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How did you fill in the front faring indentations in the tank?
Built the areas up with fiberglass to get the overall shape/ body lines I wanted then skim coat of body filler to finish it out.
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Old September 10th, 2015, 06:46 PM   #12
crazymadbastard
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looking good there!
I am a fan of cutting these motos up.
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Old February 8th, 2016, 04:46 PM   #13
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can't wait to see how those side panels turn out.
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Old October 12th, 2018, 04:42 AM   #14
cgborders
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So took me a while but I finally finished the cafe racer. I've been riding it all season and doing few little tweaks along the way. Here is where it stands now.
Attached Images
File Type: jpg IMG_20181007_155801.jpg (144.9 KB, 29 views)
File Type: jpg IMG_20181007_155827.jpg (135.6 KB, 17 views)
File Type: jpg IMG_20181007_155858.jpg (124.3 KB, 27 views)
File Type: jpg IMG_20181007_155837.jpg (164.4 KB, 17 views)
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Old October 12th, 2018, 06:14 AM   #15
dodgerdad
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Looks terrific! The tank came out perfect. Nice fender chop, too.

Can I ask you how you went about the stock gauges? I'm about to start my project and also want to use the stock ones. Would love some insight.

Thanks for sharing
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Old October 12th, 2018, 04:29 PM   #16
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Thanks.
The fender is actually a metal one of an old Suzuki I had laying around, chopped down and mounted to stock ninja fender brace- redrilled for new fender.
The gauge cluster are gs550 gauges that I gutted for the housing and lenses. I used 3 inch PVC to make up flange for the ninja gauges to sit on at the correct depth from lenses. I added the LED lights to backlight gauges and LED indicators for factory ninja warning lights. Took some tweaking to get right but worked out pretty well. Hardest part was keeping the lenses clean on the inside while I assembled them.
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Old October 12th, 2018, 06:04 PM   #17
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Turned out great.
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Old October 12th, 2018, 08:40 PM   #18
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Old October 13th, 2018, 07:22 AM   #19
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Quote:
Originally Posted by cgborders View Post
Thanks.
The fender is actually a metal one of an old Suzuki I had laying around, chopped down and mounted to stock ninja fender brace- redrilled for new fender.
The gauge cluster are gs550 gauges that I gutted for the housing and lenses. I used 3 inch PVC to make up flange for the ninja gauges to sit on at the correct depth from lenses. I added the LED lights to backlight gauges and LED indicators for factory ninja warning lights. Took some tweaking to get right but worked out pretty well. Hardest part was keeping the lenses clean on the inside while I assembled them.
They look great! Thanks for the info.
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Old January 13th, 2019, 06:10 PM   #20
Raddad70
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Talking

First love the build, I’m heavily modifying my bike and I know this is an older post (hope to still get some questions answered), but are those HD Sportster mufflers? Straight bolt on? Sound better? Performance about the same? Thanks
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