May 9th, 2016, 04:03 PM | #1 |
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Name: Roger
Location: Mitchell, South Dakota
Join Date: Apr 2014 Motorcycle(s): 1978 Z1R, 1999 EX250 Posts: A lot.
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17" wheels on pregen, how to
Did 4 conversions this spring, 3 using newgen wheels and 1 using EX 500 wheels. I didn't have much to do with the 500 conversion, but I'm sure rubbersidedown would answer questions on that conversion. This how-to is using the newgen wheels.
The front wheel is pretty straight forward, used all newgen spacers and speedo drive. Axles are the same. Had to make spacer washers on both sides next to the forks, about 4.5 mm each. I ground them to fit without putting any force on the forks and to center the wheel between the forks. DSCF002.JPG Made a bracket to weld to the existing caliper mount so it would work with the stock newgen disc, newgen disc is 30 mm bigger in dia. DSCF0013.JPG I drilled and tapped the bracket to bolt to the stock position on the fork. While bolted in place, I positioned the pregen caliper on the disc and held it in place with a little pressure on the brake lever and rotated the caliper against the new bracket and tack welded it in place. Then took the caliper apart and welded it solid, painted it and put it back together. DSCF001.JPG Rear wheel was a little more involved, used the pregen sprocket hub and cush drive rubber and spacers. If you use the newgen rubber you'll need to cut off the little rubber bridges that hold the cush rubber together to make clearance.(sorry no pics) The spacer inside the hub, between the hub and wheel, needs to have 3 mm removed to center the wheel. DSCF0001.JPG Take the 3 mm off the wheel side of the spacer, this must be a square cut or it will put uneven pressure on the bearings. DSCF0004.JPG The nose on the wheel that holds the O-ring between hub and wheel needs to be cut down so that it will just hold the O-ring in place (about 3 mm) DSCF0009.JPG Just below the O-ring in this pic, is factory machined, and just below the factory machining needs to be machined or ground with a die grinder (above the cush drive spokes) to make room for the hub to slide on the extra 3 mm The newgen wheel is still 11 mm to wide at the axle, so I took 11 mm off the outside of the rear brake caliper mounting bracket, this also must be a square cut or the caliper won't fit the disc squarely and will bind and twist when the brake is applied. DSCF0006.JPG DSCF0007.JPG The newgen disc will now be positioned properly though it is 10 mm smaller in dia. than the pregen disc (no they won't interchange) which is only 5 mm different where the caliper mounts, hasn't been a problem yet but haven't been to the track yet. I don't foresee a problem, but if someone is worried the EX 500 rear disc is the same dia. as the pregen with the newgen bolt pattern. Clean it all up and mount it on the bike, you'll need to remake the rear brake anchor or tweek it over a bit (that's what I did) and run a drill bit through so the bolt won't need to be hammered in and out. DSCF003.JPG DSCF004.JPG
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May 9th, 2016, 04:33 PM | #2 |
Daily Ninjette rider
Name: Hernan
Location: Florida
Join Date: Mar 2011 Motorcycle(s): 2007 Ninja 250 Posts: A lot.
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Motofool .................................Never ride faster than your guardian angel can fly "Mankind is composed of two sorts of men — those who love and create, and those who hate and destroy. Love is the bond between men, the way to teach and the center of the world." - José Martí |
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May 9th, 2016, 06:58 PM | #3 |
in your machine
Name: Scott
Location: Summer Shade, Ky.
Join Date: Oct 2014 Motorcycle(s): 98 Ninja 250/F12 aka ZX-2R "SERENITY", 91 Ninja 500/A5 aka ZX-5R "Phoenix", 84 Honda GL1200A "SIREN" Posts: A lot.
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@Alex this should be a sticky in the PreGen tech.
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May 9th, 2016, 11:03 PM | #4 | |
EX500 full of EX250 parts
Name: Bill
Location: Grand Rapids-ish, MI
Join Date: Jul 2012 Motorcycle(s): '18 Ninja 400 • '09 Ninja 500R (selling) • '98 VFR800 (project) • '85 Vulcan VN700 (sold) Posts: A lot.
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Quote:
If there are any doubts about the condition of the bearings, you can get a set of All Balls bearings (25-1444 front and 25-1234 rear) for about $25 total from Amazon.
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July 12th, 2016, 01:38 PM | #5 |
ninjette.org member
Name: Shoulder Blade
Location: WV
Join Date: Dec 2015 Motorcycle(s): 2007 Hoodrat 250 Posts: 242
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Thank you for this write-up.
Do you remember the dimensions of the front brake bracket? I'm in the same boat except I'll be using newgen caliper. Also, does your fender rub with the bigger wheels?
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July 12th, 2016, 01:57 PM | #6 |
The Corner Whisperer
Name: Chris (aka Reactor)
Location: Northern KY
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Nice!
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July 12th, 2016, 05:13 PM | #7 | |
ninjette.org certified postwhore
Name: Roger
Location: Mitchell, South Dakota
Join Date: Apr 2014 Motorcycle(s): 1978 Z1R, 1999 EX250 Posts: A lot.
MOTY - 2018, MOTM - Oct '16
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Quote:
I just made the bracket as I went, no real measuring or blueprint. Not likely to be the same as a new gen anyway. I'm running a Bridgestone RS10 110/70 without rubbing, trial fitted with a Metzeler 120/60 and that cleared also, #2 son has a 120/70 Michelin Pilot Power and had to move the fender up to clear. Even though the rim is an inch bigger the tires have shorter sidewalls than the 16" tires so for the most part your not changing the overall circumference. In fact the Metzeler 130/90 16 is 1-3/4" more in circumference than the Bridgestone 140/70 17 that I have on the rear now.
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July 12th, 2016, 07:29 PM | #8 |
ninjette.org member
Name: Shoulder Blade
Location: WV
Join Date: Dec 2015 Motorcycle(s): 2007 Hoodrat 250 Posts: 242
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Okay, I'll have to borrow someone with welding skills to whip up a bracket like yours.
I'm running a 110/70 Kenda, so I should be good then. Thank you.
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"Brah, you can't be looking like that on a 250, brah. You gotta mod a 250, brah. It's like the hachi-roku of bikes." |
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October 23rd, 2019, 08:56 AM | #9 |
ninjette.org member
Name: Sergey
Location: Ontario, GTA
Join Date: Oct 2019 Motorcycle(s): Ninja ZZR250 (EX250H) Posts: 213
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Just throwing it out there for a note as this is a sticky post.
Ninja ZZR250 (EX250H) were sold in Canada with 17 inch wheels. 100/80 - 17 Front and 140/70-17 rear. I have got a 2007 model. From what I can tell the parts that are related to the wheel somehow, i.e. brake rotors are the same as on newgen 250. |
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October 23rd, 2019, 10:52 AM | #10 |
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Name: AKA JacRyann
Location: Mesa, AZ
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Are centre of spokes angled laterally on ZZR250 wheels? So they form Z cross-section? Do you know front axle diameter?
I think they're same 17" wheels as 2nd-gen EX500. I've actually used EX500 17" rear-wheel in new-gen rear-swingarm on my pre-gen 250. Along with new-gen brake, linkage and shock. |
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October 23rd, 2019, 12:28 PM | #11 | |
ninjette.org member
Name: Sergey
Location: Ontario, GTA
Join Date: Oct 2019 Motorcycle(s): Ninja ZZR250 (EX250H) Posts: 213
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Quote:
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November 20th, 2019, 06:53 AM | #12 |
ninjette.org member
Name: Sergey
Location: Ontario, GTA
Join Date: Oct 2019 Motorcycle(s): Ninja ZZR250 (EX250H) Posts: 213
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