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Old October 12th, 2013, 12:15 AM   #1
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tfkrocks' Ninja 300 Rebuild Thread

Should be getting my bike back from straightening tomorrow so I figure it's a good time to start a thread.

Crash details: http://www.ninjette.org/forums/showthread.php?t=128305

As it turns out, other than the frame because super bent, the forks, triple tree, and front wheel were also a bent. Got everything straightened for less than the cost of a new frame alone though so not too bad. Would've been cheaper to pay for collision insurance in the beginning and just gotten a new bike instead but I digress...

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Old October 12th, 2013, 12:19 AM   #2
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Stripped bike for frame straightening. I circled the tail of the bike in red in the second picture so you can see how well my bike is lined up (ie. not at all). I was highly amused by how light the stripped bike is. The guy who straightened my frame typically does work for racers and has fixed up many 250s. He said mine was the worst bend he'd seen. At least it was the bike took all that impact instead of my body and I am very thankful for that.
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Old October 12th, 2013, 08:47 AM   #3
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Tomorrow as in Sunday? Sounds like you'll have 2 operation bikes soon

Were you affected by the ABS recall?
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Old October 12th, 2013, 08:59 AM   #4
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Tomorrow as in Sunday? Sounds like you'll have 2 operation bikes soon

Were you affected by the ABS recall?
Oh right I posted after midnight. Today then The 250 will be sold in the spring because I want a truck.

I got both recall notices but haven't taken my bike in because there's no point in bringing in a wreck lol. Actually Kawasaki just sent me a second set of recall notices this week. I'll bring my bike in when it's operational again.
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Old October 12th, 2013, 09:28 AM   #5
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Old October 12th, 2013, 03:45 PM   #6
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Besides the whole wreck part, an the whole costs a lot part, I like this thread
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Old October 12th, 2013, 04:14 PM   #7
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I have my 300 back and it's completely straight!

Gerry Piazza of GP Frame and Wheel in Woodland, CA did all the straightening. Great guy who did nice work at a very fair price. He also guarantees his work and said if I find anything off later, he'd fix it. I would recommend him to anyone who needs stuff straightened

Gerry described my bike as banana shaped because of how bent it was lol. Front end was 6 inches off from center. The corner of the bracket shown in the second picture had been completely bashed in to the point where it was pinching in the undertail and made it hard to remove. The tail was also off from center. Definitely an improvement now!

He did mention that the races of the steering head bearings were dented from the impact though and while it's rideable, the steering will be loose and just not very good. Looks like I'll have to get those tapered bearings earlier than expected.
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Old October 12th, 2013, 04:19 PM   #8
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The frame being bent caused paint to chip off. The tail section also had more extensive work on it so all the paint was completely gone. Repainted all the sections I could find with missing/flaking paint to prevent rusting.
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Old October 12th, 2013, 06:06 PM   #9
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Hooray... Your coming right along. I hear those bearings are the best thing since the invention of the motorcycle
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Old October 12th, 2013, 07:18 PM   #10
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I'll still wait a bit on those bearings just because I want the bike back together and I don't have them ordered.
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Old October 12th, 2013, 07:21 PM   #11
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FYI the easiest time to do those bearings in the steering when the bike is as stripped down as it's going to get. There's less crap in your way and the bike weighs less so it's easier to support on a car jack/jack stands since you'll have to remove the triple.
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Old October 12th, 2013, 10:18 PM   #12
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FYI the easiest time to do those bearings in the steering when the bike is as stripped down as it's going to get. There's less crap in your way and the bike weighs less so it's easier to support on a car jack/jack stands since you'll have to remove the triple.
Sigh... I know... I guess I'll be patient some more and wait until I replace the bearings before I put stuff back together.

I don't have jack stands so this is what I did to switch the dogbones back to stock haha. After doing that though, I want jack stands. Bricks just get in the way and adjusting the height involved getting my dad to lift the rear so I could put more towels under the bike. He didn't really like that. Anyway, bike is back at stock height with a stock kickstand.
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Old October 13th, 2013, 01:38 PM   #13
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Wow that is ghetto...... NICE!

You're a true bike mechanic once you start using ghetto solutions.

Also jackstands are like $20 at Harbor Freight for 2.
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Old October 13th, 2013, 02:01 PM   #14
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Wow that is ghetto...... NICE!

You're a true bike mechanic once you start using ghetto solutions.

Also jackstands are like $20 at Harbor Freight for 2.
More like I'm just a cheap bastard lol. I think I'll actually spend money for round two when I replace the steering head bearings. Been meaning to go to harbor freight anyway.
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Old October 18th, 2013, 10:47 AM   #15
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Removing the front end was easy enough. The bearing races however...

****ing pieces of ****, why the **** won't you ****ing come out?!
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Old October 18th, 2013, 10:58 AM   #16
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Removing the front end was easy enough. The bearing races however...

****ing pieces of ****, why the **** won't you ****ing come out?!

Be careful. It can easily turn into a mess. I know

The upper race is easy to get out. You need extra care getting the lower race out. The 37mm upper fork upper is a great tool to get out the lower race, luckily I had a bunch of bent ones in my garage.



To install the new races, go to and get http://www.harborfreight.com/10-piec...set-95853.html

Then goto Home Depot and get a stainless 1/2 rod and some nuts.

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Old October 18th, 2013, 11:28 AM   #17
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I've given an attempt on all the races and don't think I've made any progress on any of them.

Edit: YES I GOT THE TOP RACE OUT! I think I'm just super impatient lol. The new race popped right in with just a couple taps. Now to finish dealing with the bottom one and the one on the triple tree...
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Old October 18th, 2013, 03:34 PM   #18
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I am going to ****ing flip ****. I've been tapping at the bottom race on and off for ****ing hours and it's not ****ing budging
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Old October 18th, 2013, 03:43 PM   #19
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heat?
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Old October 18th, 2013, 03:44 PM   #20
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heat?
Would a hair dryer be enough?
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Old October 18th, 2013, 03:45 PM   #21
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i guess that depends on how frizzy your hair is!
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Old October 18th, 2013, 05:59 PM   #22
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Oh **** this. *pulls out dremel*
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Old October 20th, 2013, 03:41 AM   #23
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Well I finally finished dealing with the steering head bearings. **** that **** man. Didn't really bother to take pictures of the actual process since I'm not writing a DIY

I got jack stands so no ghetto brick set-up this time lol.


My bike is super nakey. I hope to never have to take it further than this.


**** loose bearings. So glad I wasn't putting loose bearings back in.


I ended up buying a damn steel rod to use on the races and it ended up being my saving grace.


I really should try to make less of a mess while working...



Final result. Since I already had to take **** off, I put on my new Driven clip-ons and SSR stem nut.


I know I'm going to have to readjust the clip-ons but handlebars are nice for moving the bike around lol. I'm going to have to get longer brake lines because the stock line from the master cylinder is way too short, though part of the reason is likely to due to adjustment. I was going to get SS brake lines anyway so w/e.

Oh and I put Vesrah brake pads in the front. Not that I have any front brake power at all right now

And now I can begin actually putting everything back on the bike! ****kkkkkkk I don't remember half that ****.
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Old October 20th, 2013, 05:48 AM   #24
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Just hope you don't have to take it apart that much ever again
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Old October 20th, 2013, 06:22 AM   #25
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Haha sounded kinda like chone when he did his bearing conversion... It doesn't sound simple at all :/
Your coming right along
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Old October 20th, 2013, 08:18 AM   #26
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Haha sounded kinda like chone when he did his bearing conversion... It doesn't sound simple at all :/
Your coming right along
Well it's a straight forward process. Execution is a bit more difficult If I had to do it again, I could probably do a better job and do it faster.
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Old October 20th, 2013, 11:07 AM   #27
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Goddammit I am good at dropping screws and then being unable to find them

Also, nice feature of the 300: the stock turn signals actually just pop in and out of a socket so my crash only knocked it out of the socket rather than breaking it. It's even barely scratched.
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Old October 20th, 2013, 11:08 AM   #28
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Old October 20th, 2013, 11:10 AM   #29
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Goddammit I am good at dropping screws and then being unable to find them

Also, nice feature of the 300: the stock tail lights actually just pop in and out of a socket so my crash only knocked it out of the socket rather than breaking it. It's even barely scratched.
I hate dropping screws... I usually wind up with a box full of baggies of all the screws that didn't run away. Losing screws is no fun at all, but screws are good hiders
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Old October 20th, 2013, 11:25 AM   #30
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I've started making a list of screws or taps and dies I need to go buy. Well at least after this whole little adventure I'll have a shitload more tools than I started with lol.
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Old October 20th, 2013, 11:40 AM   #31
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Undertail, fender, tail light, and the electrical stuff in there back on the bike (other than the couple of screws that ran off...)

The part of the undertail in the second picture got deformed because the bracket it's under was completely caved in from the crash; that corner was pointing inward instead of outward. I had trouble when I was removing the undertail because the bracket was actually pinching in the plastic. At least the bracket got straightened out nicely.
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Old October 20th, 2013, 12:43 PM   #32
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With all the tools and things I have, I still always wind up with a list of things to buy, each day is a new challenge.
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Old October 20th, 2013, 01:08 PM   #33
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I just ran into a bit of a problem. Turns out the fairing stay is bent too. It's twisted enough that I can't put it back on. I'm wondering if it can just be manhandled back to fit since it's not essential for the bike's operation.
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Old October 20th, 2013, 04:56 PM   #34
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Most metal can be bent back into shape, but I have yet to do that type of work on a bike so as to advise you any helpful tips. I always just mess with it to see the strength and how much I can work a piece then get into working with it.
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Old October 20th, 2013, 05:24 PM   #35
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Here's my fairing stay right now...
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Old October 20th, 2013, 06:07 PM   #36
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So.... Is the fairing stay bent or is the place where it mounts on the frame bent?

Both can be fixed. Likely not by you.
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Old October 20th, 2013, 06:12 PM   #37
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So.... Is the fairing stay bent or is the place where it mounts on the frame bent?

Both can be fixed. Likely not by you.
The bracket is bent. The frame is fine. I took the frame in for straightening without the fairing stay.
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Old October 20th, 2013, 06:41 PM   #38
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the frame may be straight, but the mounting point on the front where the bracket attaches still takes a lot of torque when it's hit. The bracket can be bent back using lots of muscle and leverage. If it's only slight you should be able to use it as is just remember it would point the front of your bike in a certain direction.

You could also buy a new one but they're usually over $100.
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Old October 20th, 2013, 07:20 PM   #39
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Quote:
Originally Posted by Trailerboy531 View Post
the frame may be straight, but the mounting point on the front where the bracket attaches still takes a lot of torque when it's hit. The bracket can be bent back using lots of muscle and leverage. If it's only slight you should be able to use it as is just remember it would point the front of your bike in a certain direction.

You could also buy a new one but they're usually over $100.
I think the mounting point on the frame itself is fine. The section that attaches is really both bent and twisted. I would use it as is but the sides of the bracket don't line up with with the mounting points anymore and I can't screw it down. I only looked at it more carefully because I couldn't put the bracket back on lol.
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Old October 22nd, 2013, 12:07 AM   #40
tfkrocks
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I got someone who was willing to help me straighten my fairing stay. I shall see how that goes.

Bled the front brake so I actually have front brakes which is a bit helpful for just moving the bike around. Put the cooling system back on and filled it with Engine Ice. Put together just enough of the bike for the sole purpose of hearing it run. No idea how the battery is still good, but it is. I'm going to have to take stuff like the tank back off but ****, hearing the 300 run for the first time in months feels damn good!

Oh and here is the temporary janky setup I have going on just to get things going

The stock brake lines are not long enough to get the master cylinder anywhere near level for me to fill it and bleed the brakes so I moved the clip-on way down. The coolant tank mounts to the fairing stay but that's not really going on the bike currently so I hung it on the clip-on.

Anyway, even though it's still not going anywhere for a bit longer, I'm super stocked it can turn on!
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