Repairing a totalled ninja 250R

[ninja250]

In case you missed "the good part"..
Here's my crash on video in another thread.
I bent a lil bit of everything on my 250R and am attempting a complete restore myself.
For the time between now and when I get a new frame, I'm still riding it around.. so everything will be allocated first... before the new frame. Some of the things like replacement handelbars and rearsets are now necessary before the frame to maintain ride-ability. Riding a bike around missing pegs gets old quick, although possible by storing your foot on the shift lever pivot bolt.

Started receiving parts for my "incident" run in with Mr. Guard Rail.
Didn't get to bolting much of it on yet. Just a new turn signal and a reflector for now to keep the fuzz happy and off my tail.

Need to wait for the frame and the front wheel and brake disk to show up before I get down to business really but figured I'd get this thread started.
Here's some of it..

Think I might actually have some of these pieces painted/coated along with the wheels and frame if I decide to. I'll have to look up a good local service.


Lol, gotta start small and work your way up I guess.
It still rides so I'll fix the lights first.




Sit back and watch the transformation as she gets her new makeover.

[bdavison]

Originally Posted by ninja250

Sit back and watch the transformation as she gets her new makeover.

Sit back and watch the $$$$$ fly......glad to hear your ninja will live again.

[ninja250]

No kidding.
I picked a bad time to crash.

Same day I moved into my new place and forked over the first and security deposits.
That was a hell of an expensive day. Pretty emotional one at that. Where's the waaambulence.
Crashing helicopters was slightly cheaper.

I'll post pics of all the bent stuff as I pull it off.

[bdavison]

Depends on the helicopters....Im flying Trex 450's, and looking to move into the 500/600 class. My heli's seem to break the bank more than my bike does....havent figured that one out yet.

[ninja250]

I've smacked it down with every E-heli they make in all sizes besides the 90 E-heli's. Had my share of nitros. Was sponsored by Mikado for short while there..
I'm itching to post a video (or 30) but I'll hold out.

[Snake]

Wow you have a big job ahead of you.

[ninja250]

It will be a small project but nothing I can't handle.

Pulled my front rim off to see if it was bent too, since I could see my caliper wobbling back and fourth ever so slightly from a bent brake disk.

The disk was barely bent.. I'm surprised I could even feel it in the lever.
Found the wheel to be straight though. I think the bush that tangled in the front wheel bent the disk but nothing happened to the wheel. I used a home made truing stand to test for bends in the rim.

Just saved myself $500. I guess I can send the other rim back when it arrives.

Also, found out I can get replacement fairings for my SE no problem. Looks like mine is a California only model.
I will definitely be completely restoring my bike to original finish.



Removing bent disk




Take note of red loctite for reinstallation


Culprit removed


Screw driver dial indicator trick. lol. No hops or wobbles in the rim.
The brake disk had a mark on it, so pretty sure it was only the disk that took the hit. New disk and wheel arriving Fri, but will send the wheel back or keep for spares.


Think the rearsets and clips are due tomorrow so I have somewhere to put my hands and feet again.

Also I have two good right side shogun slider bars. If anyone has two good left side and wants to trade one for one, we will both have a new set again without spending money. Holler at me if you have shogun pieces laying around. Otherwise I may write Shogun for a new left slider bar.

[ninja250]

Clips and rearsets came in.

Ordered new frame today along with Scotts damper and Yosh full carbon exhaust. This is gonna be wicked.



Garage is a mess

[BlueRaven]

Wow the last pic didn't look like a ninja at first glance

[Betlog]

Clipons, rearsets, dampers, yoshi exhaust. Dang KC, you're going all out. I can't wait to see the finished product.

[Betlog]

BTW, do DIY for the rearsets. I've read a few threads here about fitment concerns.

[Flow]

It didn't look like a Ninja after any amount of glances. I have a feeling this will be a very entertaining thread.

[ninja250]

If I told you guys I was going to be riding that 250 tomorrow you probably wouldn't believe me but I am. Lol
it won't be anywhere near done being rebuilt though.
I've torn the whole bike apart so many times I can get it naked like that within an hour or so.

I'm going to have the prong for te Scotts damper welded to the new frame before it's painted/coated which should be awesome.

Will let you know about the rearsets. If they don't fit I'll figure out how to make them. If necessary I have a mill and can modify them.

My new front rim, axle and brake disk will be here today too. Gonna try changing my own tire for the first time at home. If I did it right I think the new rim coming already has the red decals on it to match my bike like the stock rim did. May not powdercoat the rims but will surely do the frame while it's naked. Rims could come later.

Almost forgot... I need to research fork oils and springs. Absolutely necessary.
Posted via Mobile Device

[Kurosaki]

I believe you.

Stripping the 250 down is not terribly hard or time consuming once you know what you're doing. Everything comes off rather quick.

[ninja250]

No problem with the left (shifting) side.. and I like to run my shifter loooow.
Other than the fact that now my kickstand looks ugly and I want to cut it off. lol

Then I wouldn't be able to park anywhere though. Ah well.

The directions included with the rearsets pretty much covered it, no need for a DIY.

On to the left side. I should have bought these sooner. Just don't know how I'll like the new lifted back stance but I guess I'll find out.



middle


down


up

[ninja250]

Right side on there.
No problems to speak of really. Just a little tricky to get it all together.
Had to bend the exhaust heat shield a hair to gain clearance. No biggie.
Also was able to mount the brake light sensor still by modifying the spring and mounting the brake pedal return spring post on top of the brake pedal sensor bracket.

Might want to shorten my brake reservoir line in the future. Don't really like that kind there. Another no biggie I suppose.

Was just informed my frame is going to be a bit while longer than I thought for some reason. I think they'll have to drop ship it. I can't really see UPS or USPS ringing my doorbell with the frame I suppose.





The rearsets look good. They'll get my endorsement but I've never had any others so have nothing to compare them to.

Time to do the clips.
Riding around a bent frame in the mean times sucks.

[ninja250]

New rim, disk and axle.
Just gonna put the new rim on. Screw it.
Need some new tires for that first.
Funny how the motto fits so well on a box for a wheel.

[ninja250]

Damn. Forks are bent. Left fork leg is anyways.
Went to straighten them out more and twisted the tube in the tree only to watch the wheel wobble back and
fourth. I must have been going faster than I thought to total the entire bike like this. I didnt think it hit quite this hard!
Looks like I'll have to pass on tomorrow.
Posted via Mobile Device

[adri99an]

Looks good KC--my bike is next?? You like a pro doing all that work

[ninja250]

Ill have to pass on tomorrow bro. My forks are bent.
I'm already counting my blessings from my last gmr run scraping knee with a bent frame and fork and no pegs. Lol
the second she is running again I'll be there to pull off your fairings and do yours!

Dang I might jut go buy another bike now. Lol
take my time bolting the beater back together.
Posted via Mobile Device

[Cedilla]

Man it looks like the money is flying out of your pocket with the quickness. Good luck with getting everything straightened out.

[Dano]

since you are going all out and rebuilding the totalled bike, what about sourcing some better forks. or send yours to racetech and have then redo them right for your weight and riding style.

[ninja250]

Yup..
Going to order spring and oil and new fork blades and fok tubes. About $500.
Wouldn't want to ride this bike on the track with stock forkdivers At higher speeds anyway.
Pretty sure thts what cause the crash. I would have made the corner bad line and all if the forks didn't dive me into traction loss.
Pretty sure I didn't slam on the brakes... Just feathered them like usual. Still dove like crazy.

Will be doing all the work myself however.
Might go try and apply for a gsxr 750 in the mean time for my highway commuting from riverside to la every other day.
I know how to ride just fine when I'm not playing on my knee. Still probably work out to be less than driving my F150 so much.
Posted via Mobile Device

[ninja250]

Pitted triple clamp races..
Not sure if I bent the triples yet or not.
This sucks.






Here's a part you don't see off your ninja all too often.


Oh yeah check out my curves.


I could feel the steering had a built in "self centering mechanism" after the crash.. which shouldn't be there at all. Which led me to discover this lil issue.

[Postiez]

Thats a lot of work, I am jealous of your ambition and skills. Keep it up!

[ninja250]

Replaced the steering bearing races and added the clip ons.
Awaiting the frame and fork pieces.
Gonna take it out for a spin today. Still has old front wheel and old bent brake disk on there for now.

Rode it for 5 mins last night around the neighborhood. The clip-ons feel totally weird.. not used to them yet. Need to take it up to the twisties and get a feel for them. Also the reasets pegs have amazing grip! Far from the slippery ebay pegs I had no problems with, so have to get used to all the grip now too. Hard to explain unless you were used to the slippery pegs.

The clip-ons do make the bike wiggle when decelerating without hands on it, like I have heard elsewhere. No surprise, they are tons less weight than stock. The bike did it before with the stock bars too, but basically unnoticeable to the untrained.

back in one piece


clip ons


rearsets




blurry clip on shot

[ninja250]

Need to adjust the right rearset brake pedal to run lower.
Also was not able to get the shift lever as low as I'd like it due to the kickstand kill switch mount but it's not that far off and I'm really tall so like it really low anyways. No issues to speak of with any of Woodcraft's offerings so far. They seem solid and good quality to me.

I actually like how the right hand rearset allows flexability between the brake pedal and master cylinder to help smooth out the rear brake. Hard to explain that one without showing it in person.

So basically all I have left to do is get the frame and forks, maybe some engine mount triangles and she will be all straight again. then the front upper cowling needs to be replaced as does the rear left and front lower left. Then she's all back to normal again and will get tires and a Yosh and the Scotts. Also the fork changes.

Haven't figured out how I'll do the engine swap yet. I guess either set it up on a built-up pallet with some 2x4's or I'll grab a cheap "cherry picker" from harbor freight and attach the chains to some old crappy engine mount bolts. Knock on wood but the engine seems to be running even better after the crash. Go figure. That's how you really break it in.

Now I really do know how to rip this whole bike apart. Everything but inside the engine..

I did get my iphone mount and charger mounted to the clip-ons as well after the photos. I'll get pics of that later.
I downloaded a special airplane cockpit dash on my iphone that adds tons of gauges to my bike in real time, so it's just like added displays really. I don't text and ride so put the iphone on the right side this time to prevent me from using it with my throttle hand while driving.

PITA knowing I have to rip the bike apart again when the frame shows up.
What color should I have it painted?

[ninja250]

A little squeak developed in my bike after another 1000mi after the crash.
Kinda like a Beep beep beep beep beep really quick and pronounced and consistent at 35mph. It's speed would increase as I increased speed and it would decrease as did I.

Since I am still using the bent brake disk on the original front rim, I removed the front brake system entirely and tried again for squeaks. Still there.

Then I removed the fairings and speedo cable and tried again for the squeak. Still there.

I'm pretty sure the only thing left in the front of the bike that could be making that noise is a bad wheel bearing from the crash. Which gives me an excuse to put the new wheel, axle and new brake disk on that I already have.

I didn't really want to put them on yet until I had the new forks and frame together but would rather do it now than have the front wheel seize up on me in another 1000mi.

Still no show on the frame, exh and damper yet and still finding busted parts.
No matter, only means more to replace and upgrade.

[Locksmiff]

So what exactly on the bike WON'T be new items

[ninja250]

engine/trans, cooling system, electronic harness and battery/regulator and charging system, rear wheel, seats, tank, some of the plastics..

everything but the frame, forks, headset, front wheel and disk, stock rearsets and stock handlebars will transfer over. Also gonna ditch these crap tires.

So far I've lucked out and don't notice any probs with the engine/trans/cooling. Crossing my fingers bigtime. To be honest I put 1000mi on it after the crash and it feels better/stronger/smoother than before I crashed it.

I'll have a heck of a lot of parts laying around afterward. Trying to decide if I should buy another bike or not right now. I don't really want to pay for another new bike but I don't like buying other people's used equipment either.

Either way my ninja 250 will ride true again eventually.
Right now it's like a box of Legos. Pieces everywhere.

[ninja250]

Wait till you guys see the frame when I finally get it stripped.
It's all bent up all over the place.

Can't help but kinda laugh when I see it then I kick myself a few times directly afterward.

Also the fork is bowed pretty good I'm willing to bet. I'll have some crazy crash parts pictures to show off sooner than later.

[DEXSPEED]

KC,i noticed you said something about you having access to a milling machine?maybe you can help me with my 650r rear wheel mod if you have time.

[maglin]

Thank you for the great write-up with all tese fotos!

And a question: Have you asked Kawasaki what is the cost of the frame brand new?

[ninja250]

Originally Posted by DEXSPEED

KC,i noticed you said something about you having access to a milling machine?maybe you can help me with my 650r rear wheel mod if you have time.

I have a small mill but will help out if it can handle the job. Let me know what you need taken care of and I'll let you know if it's possible I can help
It's just a little mini mill but it might be able to handle the job.. depending.

Originally Posted by maglin

Thank you for the great write-up with all tese fotos!

And a question: Have you asked Kawasaki what is the cost of the frame brand new?

Nope.
Went online..
Less expensive than Kawi dealer.


Just need all my fork parts and tires.
Then plastics. And this biatch is back to 100%
Only had to pay for it twice..

[Alex]

What site did you find those discounts at?

[Momaru]

looks like the cheapcycleparts.com GUI

[ninja250]

Yup..

Last time they shipped the wheel via FedEx and the guy delivered it as I had the garage door open, working on the bike. I opened the package right there in front of him to inspect my wheel was all good and he was asking all kinds of questions.

Basically told him I wrapped the bike up in a guard rail and he might be bringing me a new frame too. He was trippin'.

Good to be in tight with the delivery guy though. Next time I'll throw him a cold drink like I do with UPS and USPS. Last time I had a fresh coating of grease all over me and didn't want to get the house dirty.

[DEXSPEED]

http://www.newninja.com/modification...-rim-and-tire/
not sure if you have seen this?just need to mill the rear brake caliper hanger thinner to accommodate the 650r rear wheel.if you have not seen this post look into it then you will see what needs to be done and you might like this mod too.thank's in advance.you can charge me a fair price for the job if need be.

[ninja250]

If you are referring to the black piece in the pics below, I can probably do that milling. It looks small enough anyways. I'd have to put the piece in my mill and see how it likes the material. Do you have the piece?
I'll wait for you to do the mod and see how it comes out, but I can probably mill your part for free. Looks like a quick afternoon job.

These are before and after pics right?

[DEXSPEED]

yes the caliper hanger that needs the shave.i'm buying one hanger in ebay.if you are busy i know ur rebuilding right now,no rush.thanks