Race bike for the street

[Racer x]

As some may know I built a new bike. Project X is a great bike and though it did not perform as I hoped the first time out. I feel the potential is there.

My first bike the Kawmerachi 250 has been hanging on the wall. I have decided to return it to street use. I see a lot of cafe racers and bobbers here in Iowa City and figure it will be a blast to ride. So what do I need?

First I will need lights and brakes tread on the tires. Basic safety items. And legal issues.
To start I need a new wiring harness. I found one for 15 dollars on E bay.

I have almost everything else in my pile of parts. So I began gathering stuff. Blinkers brake lights headlights .

What I don't need is nitrous a steering shock or an extended swingarm. So simple is the rule.

Let's see how far I get putting this bike back on the road.

[Alex]

Good luck with the project!

[Racer x]

I made an amazing amount of progress yesterday. I spent a huge amount of time just hunting and gathering parts. Stupid stuff. Like I started looking for six magnets to mount my Koso dash speed sensor. Then I remembered I got a pick up the mounts to the stock speedo drive. So then I spent a bunch of time looking for that. Never found it. Then I went looking for a stock speedo drive. Nope. That was a couple hours. But I did get a lot done.

The race fairing is a problem. First it is not mounted with road bumps in mind. Second the handle bars are very very low. Third there is no real place to mount a headlight or blinkers. I guess blinkers could be hung on. But I am not keen on cutting the fairings.

The stock tire is very large. And old. I am going to look for a smaller front tire. Maybe a 100 instead of the 110. Otherewise the front fender will needs to be remounted slightly higher.

Now I am waiting for a wiring harness and a fuel fitting to block off the tank that was used for nitrous.

I will have to think about the headlight situation. But I am leaning toward no fairing.

I also need a brake light

[sharky nrk]

Well despite the irritations, I can't wait to see it - that bike oozes cool to me.

[Racer x]

This is what I have so far.
I decided I just can't run the front fairing. It cost 500.00 plus the windshield, plus paint and mounting brackets and stickers. I would have to cut it up really bad to put a headlight through it. And the bars are low and the dash is in the way of the cables and bars.

I might want to reuse it later and I can't bring myself to chop it up.
That is fine.
New plan is a cool 1/4 fairing mounted to the bars. Or no fairing at all. This solves all the clearance issues. The light and blinkers and the dash will all pivot with the fork.

I got a wiring harness for 15 bucks and it went in with no problems. There are a couple wires that need to be repaired . But I knew that when I bought it. I have plenty of old wiring harness pieces . So the wiring is sorted. Just some tidying up to do. And relocate some stuff. I want to hide as much wiring as I can.
The rear body tag and bits are done. But I want to buy a hugger.
Bars are done
Fuel system is done
Front and rear brakes are done. Still need a brake light.

Still need to weld together a longer kick stand tomorrow and make a shift lever for GP shifting to fit the drop pegs.

Next week I will order the headlight stuff. And I need to come up with a fender for the front.
Then tags and insurance.
Should be rolling soon.

[csmith12]

Nice progress!

[mgentz]

awesome job.

[Dave Wolfe]

Sweet! Its begging for a rider with an open face helmet and bomber goggles.

[Racer x]

I never thought about that. But you are right.

[Panda]

Originally Posted by Racer x

.

What I don't need is nitrous a steering shock or an extended swingarm..

I can only assume by this that you mean you don't need the little nitrous bottle and tiny extended swingarm you currently are using and that you are going to go bigger with both.

Good luck with the project and keep posting pics!

[Racer x]

No I'm not going to use nitrous on this bike. I will be riding this bike to work and as a regular bike so the stock swingarm and chain is fine. Besides I am keeping my other bike for land speed racing. It will have the extended swing arm and nitrous and be used only in the 250cc class.
The only reason I extended the swingarm is to make room for things under the tail section.

With the cafe racer I like the simple see through look. So my goal is to hide as much as possible.

Update on progress.
Today I made all the parts for the kickstand and shifter and ordered a headlight bracket.

[Racer x]

Today I welded the kickstand and shifter. Now I am cleaning up the kickstand for paint. Tomorrow I'll finish that up.

I also ordered brackets for the headlight. I want to get them installed before I find a headlight. That way I am sure of te spacing.

I also found a tail light I like. It's 75.00 on e bay but I really like it. It looks like two shot glasses with a screen covering led lighting. I think it will be cool.

I also finished up soldering up all the wiring. Now I just need the key assembly. It was 12 bucks plus shipping for an aftermarket key assembly. That is not bad. I still need to figure out a front fender and a dash board. But don't need them to get on the road. Also a rear hugger is 40.00 and I will get that after I am street legal.

I am running a totally stock engine and made up a nice set of stock carbs. That way I have a choke and they should idle at 900
RPM with good response. I am using a custom made dual exhaust wth pod filters ad will change to a K&N 0990 filter later.

For the ignition I will run a stock 2010 unit. This will be a real show bike with little go fast stuff. Should be fun.

[Racer x]

Today I finished the kickstand and bypassed the kick stand switch.
and I installed the shifter(moto GP style)

I installed stock carbs with a fuel filter and mounted the stock choke.

Touched up a little paint on the frame and cleaned the shop. Next step is to mount the starter relay and ignition module perminitly. Then the battery hold down. Once I get the key I will test everything and then tie up the wiring. I hate zip ties but they work.

[HoneyBadgerRy]

Originally Posted by Racer x

I am running a totally stock engine and made up a nice set of stock carbs. That way I have a choke and they should idle at 900
RPM with good response. I am using a custom made dual exhaust wth pod filters ad will change to a K&N 0990 filter later.

I could get my bike to idle at 900 rpm (when it ran) however it seemed to have much better throttle response if I set the idle to 1500-1700 rpm.

Why change from the K&N 0990, I have the K&N, and kinda prefer the 6" uni filters. Not enough to not use the $50 K&N and but something else, but its an opinion.

[Racer x]

I like the 0990 because it has little velocity stacks built in. On the dyno it did very well. Pods do not do well and nothing at all was the best. So for street I will go to the single 0990.

I don't really care about idle speed. But the race carbs likes 2000 or more. I think the quit lope will be nice

[HoneyBadgerRy]

I didn't know the K&N had velocity stacks. That's cool, I guess I will keep them.

[Racer x]

They are small. But the I think the big single filter acts a bit like an air box

[Racer x]

The beast is awake. Today I turned the key. Started dash,horn and blinkers all working. I spent all day mounting the battery and the various components. Just a little more wiring to secure.

Still left is the headlight. But I need the bracket first. Then I can mount the RX 2 Koso dash. I might go for a dual guage set up later. I like the look of seperate tack and speedo. I found some cheap on eBay but none that read MPH. I can live with the KPH for the price. But first the lights.
Also on the list is the tail light and front fender.

This is the tail light I am thinking about



https://www.ebay.com/itm/331875656061



Sent from my iPhone

[Flying]

That is a banging location for the battery!

[Racer x]

Big day today progress wise.
Ordered a hugger. 40 bucks on eBay. That is a good deal on a used piece. It was much more new. And it is just like the one I have on Project X so I know it will bolt on the the chain guard and the swing arm is already drilled.

I ordered a headlight , tail light and front blinkers from work. Parts Unlimited stuff. Not expensive and I get a discount. So it was cheap and I can return it if it won't work.

I also did more work with the wiring. Just details like Velcro mounting relays and wire repair for a damaged plug.

I also mounted the front fender. This was a bit of a pain but it is done. Mostly done. I actually need to pull the fork. Replace a seal change the fork oil and put it all back together with lock tight. But that is no big deal. I am also thinking about rubber fork gathers. Just for that retro look.

Now it is just a matter of finishing up the lights. Buying merrors to attach to the bar ends and add fluids. I tried bleeding the brakes. I need a rear brake reservoir and I think the front caliper is dragging. So I need to work out those bugs while I wait for the lighting parts. Also oil and antifreeze.

Once the lights are in I can make a dash bracket and mount the dash.

[Racer x]

I am making up the dash bracket today and tomorrow. I use a high tech CAD system for my design work. Cardboard Aided Design

[csmith12]

Originally Posted by Racer x

Cardboard Aided Design

Nice work sir.

[Racer x]

The dash bracket is done. And I installed my Koso Rx2 dash. I mounted the speed sensor and all the temp sensors. That is a big item checked off the list.

Now it's just some lighting and the wiring work to button up. I got the headlight and blinkers today and I should get the mounting bracket tomorrow. The light is a seven inch round light with a nice metal housing. I am very suprised at the quality of EMGO stuff. Really good and the price is very reasonable.

[HoneyBadgerRy]

The cover on the upper triple looks amazing.

Looking at a couple ninjette cafe racer threads recently really makes me want to do something of that scene. At least naked. No idea what I would do with the rear lights and seat though.

Anyway, I like the way this is turning out. Good job and good luck.

[Racer x]

Thanks ,I think the cafe racer thing is a bit over done now. But I have had this bike for eight years now and hate to see it just hang on the wall. This is a really cheap build. But only because the major work was already done.

[Racer x]

Headlight and blinkers are in. Woo hoo!

Now I just need some oil and antifreeze to make noise. I don't know if the headlight works till I start it. But I checked the wiring and that all seems good so I am hopeful.

Now it's just the rear fender and taillight befor I'm on the road.

[Racer x]

Made a new shifter lever. I did not do the drilling. But flipped the linkage I've so it shifts GP style.

[Racer x]

The bike is running. I had a problem starting up! No spark. Seemed odd. As everything worked before. I began checking the wiring and fuses and everything checked out. So I just had to plug in my BRT ignition system. This was not somthing I want to do because I need it for my race bike. So now I really have no chose but to convert it to the tried and true 88-94 ignition box. Not a big deal. I will do it later but I wanted to use the stock ignition system.

The sound is very loud but it is not really bad and Iowa has no inspection. I don't go to work early so I will run it.

https://youtu.be/m0YcOVSQEtI

[Racer x]

Out doors glamor shot.
Still need to swap the ignition box and mount the headlight. Also the headlight need a tiny bracket to hold it in place and make it a solid but adjustable unit. But that is the only things left before the first ride on the street for this bike in six years.

[Dave Wolfe]

That turned out great! Nice work.

[HoneyBadgerRy]

Originally Posted by Racer x

So now I really have no chose but to convert it to the tried and true 88-94 ignition box. Not a big deal. I will do it later but I wanted to use the stock ignition system.

The 88-94 ignition box is different than the 89-07? I remember having a thread on this and the only different boxes were the CA box, the ZZR/GPZ box, and the 86-88 box.

[Racer x]

I think the specs are the same. But the pin wiring at the plug is different. All the colors are all the same. Disregard the gray. All the colors are the same but the red wire on the pre gen box goes to the brown wire on the new gen wiring. And it starts and runs.

[Racer x]

This weekend I did some minor refinements to the bike. I calibrated the speedo. The Rx2 is nice that way.
I also adjusted the hand controls some for better feel.

Then I replaced the stock engine with a 282 cc race engine. This engine is bored 4mm. Plus 12.5 to 1 Pistons. Two intake cams set at 104 deg. And a ported and polished head. It has a Barnette Carbon clutch. But I went to stock springs since I don't use nitrous on this bike it will be fine. The heavy springs made neutral hard to find and sitting in gear Boggs the engine.
First ride was very impressive. I changed the gearing from a 14 tooth sprocket to a 15 tooth sprocket and it feels great. Pulling past 70 in third gear with ease. I did not go any faster because of the speed limit.

The other thing I needed to do was make a baffle for the gas cap. It is a hole drilled in the screw on cap. The bike pulled so hard in first and second gear fuel splashed out of the vent hole. That has never happen before. I really need to get this bike on the track again. But riding to work every day is so much fun.

[Racer x]

Yesterday I went out on the highway. 70 mph speed limit and wide streight flat roads of Iowa. The 282cc engine runs hotter than a stock engine.
This is the first time I have ridden this bike set up on a super slab and over all it felt great. But the radiator is smaller than the stock one and made of brass not aluminum. So at 75-89 mph for two or three miles I watched the temp climb to 205-209 deg. When I let off it went streight back to 199-200 which is normal for street cruising. Though the stock engine ran at 189 .
The radiator is designed for aerodynamics and to fit inside a closed fairing. Then only ride one mile. So I don't feel bad that it is not the best or most efficient cooling radiator. I don't think I will change it. But I might look at rejetting the carbs one jet richer to see if that change the normal riding temp at all.

The power felt very good. From 60 I could leave traffic way behind just by turning the throttle. And it pulled smooth up to the 90. Going past tractor trailers felt good. The riding position is classic flat back tuck . The now empty aluminum tank lowers the center of gravity. So the bike is stable. I did not feel and air blast passing trucks. Cars are all cruising st 75 plus so I was bairly going faster than the flow. Just zipping past the trucks.

[Racer x]

I have been riding this cafe racer a lot since I rebuilt it for the street. It performs really well and is a huge amount of fun. It is fantastic to be able to test and tune the engines for my race bike and I love it.
The only complaint is the riding position. It is still a race bike and puts a lot of weight
On my wrists. Good for a mile ,but long rides are not great. Plus the flat position is not good for visibility and law enforcement may frown on a rider in a full tuck . As opposed to a more upright position at the same speed.

So I decided to move the bars from below the top fork clamp to above the clamp. I moved the forklegs up about 1/2 inch and clamped the clip on bars to them. This tiny change transformed the bike.

Now I can actually take my hands off the bars . I am not forced to use my stomach mussels to support my body.

From the the stock 250 ninja these are the total changes made.
The rear suspension is up one inch. I used different links for this. Front is down two inch. The custom 1.5 gallon tank is Five inches lower than a stock tank.

Seat is down about four inches. The whole rear section of the frame is custom made . The bars are four inches lower than stock. And the foot pegs are down two inches and back one. This makes the bike very thin and low. It feels super nimble and weighs about 310 lb with fuel.