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Old August 21st, 2016, 10:25 AM   #41
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Having a go at cleaning the carbs... Soaking in Pine-sol overnight per Ninja 250.org suggestions.
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Old August 26th, 2016, 12:19 PM   #42
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The front brake pads were replaced, and brake fluid flushed both front and rear.


I installed a used 2nd gen Ninja 250 rear shock that I had from another bike.


The carbs are almost ready to go back in.
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Old August 26th, 2016, 05:20 PM   #43
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Wait am i reading it right , the bike did run with that nasty carb?
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Old August 27th, 2016, 07:13 PM   #44
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Wait am i reading it right , the bike did run with that nasty carb?
Not with these. I had a spare set that I installed for the initial test run.
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Old August 27th, 2016, 07:21 PM   #45
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Carbs cleaned up, reassembled, and installed. Not bad for my first try. And the best part - they run now!

I tried 2 different kits - one brand name, and the other I had never heard of before. After examining, and installing both kits, they seem to be the same.

The Kaizen 112-2501 kit is almost 1/2 the cost of the K&L kit.
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Old August 29th, 2016, 07:05 AM   #46
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Wow! What a difference clean carbs make. I don't even need choke, nor throttle, and it fires up instantly every time.

I need to service the carbs on my main bike now.
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Old August 29th, 2016, 01:27 PM   #47
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If you don't need the enrichers when starting, it might be good to double check your idle mixture screws. When I set mine for highest idle when hot, I need the starter lever for a few seconds to get it going when cold.
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Old August 30th, 2016, 08:13 AM   #48
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If you don't need the enrichers when starting, it might be good to double check your idle mixture screws. When I set mine for highest idle when hot, I need the starter lever for a few seconds to get it going when cold.
I set them at 2.5 turns, but I will keep your suggestion in mind. Thank you.
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Old September 14th, 2016, 10:58 AM   #49
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Progress has been eeking along. I do need to use the choke to start it every time now - which is normal, compared to my other running, riding 250.

I have swapped over a good set of used wheels / tires that I had in my cache.

I am finishing up painting the plastics, and hope to have this refurbishment completed by the end of September. I thought that I would have this entire project done within 2 weeks!
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Old October 11th, 2016, 06:06 AM   #50
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The project is almost complete! Yesterday, I took the 250 out for a test ride on the highway. Everything is working great!

I'm just buttoning up a few minor last items, and then to install the recently painted fuel tank, and upper / lower fairings. No pics until it is complete. I went with a different color scheme than it came with, as I used those plastics for my "main" 250.
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Old October 11th, 2016, 06:13 AM   #51
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Oh. I swapped in a pair of used 300 front fork springs, sourced from one of our members here. The ride is much improved now.
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Old October 23rd, 2016, 07:37 AM   #52
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I swapped in a good used pair of clutch / brake levers.

All that is left to do is clean the inside of the tank, install it and the upper and lower front fairings, and the refurbishment is complete!

Pics to follow...
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Old November 8th, 2016, 06:37 PM   #53
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I installed a fuel filter, and replaced the fuel line ( 5/8 inner diameter ) - for good measure.
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Old November 30th, 2016, 09:14 AM   #54
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Its almost done! I just need to clean the fuel tank one last time and install it...
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Old April 17th, 2017, 08:08 AM   #55
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Finally Finished!

The project is finally complete! It was a long, slow winter, but the MC is ready for sale.

To recap ( I'm sure I am forgetting a few things ):

Intentionally left all stock
new-gen 250/300 front springs and rear shock
All fluids changed
new brake pads front & rear
cabs cleaned & serviced
petcock rebuilt
fresh / custom paint - black and silver ( nothing special )
good used tires

Everything works; ready to ride for the new owner.

* EDIT - I also did:
valves adjusted
spark plugs replaced
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Old April 17th, 2017, 08:18 AM   #56
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It looks great! It seems a shame to do all that work, make it look that nice, and then sell it. Especially since I bet you'll end up with about $2/hour for your labor.
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Old April 17th, 2017, 08:22 AM   #57
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Thank for the feedback! I bought it with the intention to sell. Yes $2/hr - if I am lucky! I won't be quitting my day job to do this on a regular basis.

I still have 2 others that I am working on, and hope to have the next one ready for sale within the month.
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Old April 18th, 2017, 10:46 PM   #58
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Agreed. I need to IMMEDIATELY rinse it.
I suggest using a non-acid based rust removal solution like Evapo-Rust. These solutions are organic based rust dissolvers that chemically attack the iron oxides (rust) without attacking the base metal. There's another product called Rusteco which I have not used. You should be able to find Evapo-Rust at Auto Zone and Amazon. It isn't cheap at around $30.00/gallon. You might need to do the loose nuts cha-cha with this stuff also just to make sure there are no cling-ons left behind.


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Old April 19th, 2017, 06:23 AM   #59
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Don't throw away the used Evapo-Rust. It looks dirty, but works many times.
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Old April 19th, 2017, 06:35 AM   #60
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Don't throw away the used Evapo-Rust. It looks dirty, but works many times.
Thanks TJ. I forgot about that. I used it on the O.E.M. mufflers that came with my bike and after a coat of Mothers car wax they look very good. THEN I go out and buy some Yoshimura slip-ons. Go figure.

Cheers,

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Old April 20th, 2017, 09:09 AM   #61
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Nice build there slugger.
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Old May 1st, 2017, 12:34 PM   #62
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Nice build there slugger.
Thank you Evan
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Old May 5th, 2017, 04:47 PM   #63
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SOLD!
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Old November 10th, 2017, 11:52 PM   #64
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When I was your age we put rocks and sand in there with some kind of juice and shook the tank like our life depended on it.

Sweet fix up
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Old November 11th, 2017, 12:09 AM   #65
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Parts from this conglomeration, and this matched set of fairings most likely will be incorporated into the project.
Awesome Rejuvenation ! thanx fer the inspiration !
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Old November 11th, 2017, 12:48 AM   #66
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Parts from this conglomeration, and this matched set of fairings most likely will be incorporated into the project.
what a great machine !
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Old November 20th, 2017, 06:29 PM   #67
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Awesome Rejuvenation ! thanx fer the inspiration !
I'm glad that this build thread inspired you.
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