Race Bike Build

[Mark Cook]

OK since I'm working on building up a little racer too, I'll add to the merriment.
Here is what I've started with.
Basically a pretty rashed street bike with about 8500 miles on it.

[Mark Cook]

At home in the shop.

[Mark Cook]

And the Teardown begins.

[Mark Cook]

Forks being prepped for emulators, springs and preload caps.

[Mark Cook]

Quick mockup with bodywork to drill mounting holes.
This was a cheapy set off of ebay. Not bad for the cost.
Mounted forks to check for fitment of woodcraft clip-ons.

[Mark Cook]

And as it sits today.
Now to get started on stripping out the wiring harness and putting it all back together.

[CC Cowboy]

So I'm following your progress. I look at each of your posts and noticed the time stamp on each and the amount of work done. Damn, you're fast at this rebuild. At this rate you should be done at about 10:00 tonight.

[Mark Cook]

Mad skillz!

[Mark Cook]

Pretty busy in the garage today.
Installed the woodcraft clipon riser spacers. I'll see if I truly need them when the triples arrive.
Installed the Moto X rearsets on the frame.
Fabbed up an engine stand, and tore down the top end for inspection. The cylinders look crappy, so I need to figure something out for a replacement. Will need to keep things stock for MCRA legality.
Installed the woodcraft sharkfin.
Also installed the tapered steering bearing races.
Overall a productive day.
More parts should arrive next week to allow more progress.

[NINJosh.]

Originally Posted by Mark Cook

Pretty busy in the garage today.
Installed the woodcraft clipon riser spacers. I'll see if I truly need them when the triples arrive.
Installed the Moto X rearsets on the frame.
Fabbed up an engine stand, and tore down the top end for inspection. The cylinders look crappy, so I need to figure something out for a replacement. Will need to keep things stock for MCRA legality.
Installed the woodcraft sharkfin.
Also installed the tapered steering bearing races.
Overall a productive day.
More parts should arrive next week to allow more progress.

hey Mark, i'm assuming the "sharkfin" is the thing mounted on the swing arm, what is that for exactly?
also, could you hook me up with a picture of your upper frame crossmember. it kinda looked in one of your photos that yours is crooked the OPPOSITE direction that mine is. i was kind of worried about mine being crooked at first, but the more frames i look at the more they all just look crooked.
the picture makes mine look a little worse than it really is but you see what i'm getting at.
good work man, can't wait to see it all put back together!

[Mark Cook]

Sure thing. I'll head out to the garage later and take a shot.

The sharkfin is to protect in a crash in case your hand or foot gets caught in the chain.

[Mark Cook]

Let me know if this helps.

Originally Posted by NINJosh.

hey Mark, i'm assuming the "sharkfin" is the thing mounted on the swing arm, what is that for exactly?
also, could you hook me up with a picture of your upper frame crossmember. it kinda looked in one of your photos that yours is crooked the OPPOSITE direction that mine is. i was kind of worried about mine being crooked at first, but the more frames i look at the more they all just look crooked.
the picture makes mine look a little worse than it really is but you see what i'm getting at.
good work man, can't wait to see it all put back together!

[NINJosh.]

Originally Posted by Mark Cook

Let me know if this helps.

well, your's looks pretty good. it's definitely angled the same direction if it's angled at all. it look different in one of your early photos from the side of the frame. thanks again man!

[krakatak]

Looks like fun. If you need an extra set of hands, let me know. Glad that the rules are sorted out for next season, can't wait for the racing to resume...

[JohnnyBravo]

I love da builds

[Mark Cook]

Yeah I'll have my hands full after Sunday.
SV motor will be done, and I'll start on the SV/Ducati hybred.
Let's see... What else can I build?

Originally Posted by krakatak

Looks like fun. If you need an extra set of hands, let me know. Glad that the rules are sorted out for next season, can't wait for the racing to resume...

[Mark Cook]

Brief update as parts start arriving.
Triples and forks have been mounted as well as clip-ons. Will have to wait till I get the bike further along so I can sit on it and get the bar angles and heights correct. I really dislike the bodywork limitations with the clip-ons though...

[r6boater]

Cut it. Draik run clip-ons sans risers but we had to cut the bodywork to get them to be able to work.

[Mark Cook]

Yeah, I'm considering that, but will need to wait until I get closer to completion before I start cutting...

Originally Posted by r6boater

Cut it. Draik run clip-ons sans risers but we had to cut the bodywork to get them to be able to work.

[Greenlawnracing]

Looks great! Where did you get the fork caps?

[r6boater]

Originally Posted by Greenlawnracing

Looks great! Where did you get the fork caps?

Sling Shot Racing sells them.

[shane liberty]

Fun build man.


Whatever you do DO NOT CUT THE SUBFRAME!!!!


Seems like a great idea to shave weight and to avoid the subframe smacking the ground and bending, but it's illegal. You're not allowed to chop up or shorten the frame in many supersport rules from different organizations. A couple of us, ahem, have made this mistake.

[Mark Cook]

It's actually legal here in St. Louis with MCRA. I still may cut it, but need to look closer at how strong the tail will be without the rear mounting points...

Originally Posted by shane liberty

Fun build man.


Whatever you do DO NOT CUT THE SUBFRAME!!!!


Seems like a great idea to shave weight and to avoid the subframe smacking the ground and bending, but it's illegal. You're not allowed to chop up or shorten the frame in many supersport rules from different organizations. A couple of us, ahem, have made this mistake.

[Mark Cook]

Some progress yesterday since it was snowing like crazy.
Engine is bolted back together and bolted in the frame. Exhaust test fitted as well.

[Greenlawnracing]

Originally Posted by Mark Cook

It's actually legal here in St. Louis with MCRA.

True, but you make a trip to CMRA or CCS which are in your backyard (ok, more like left field) and you won't be legal in some classes.

[Mark Cook]

I realize that, but since MCRA decided to have their own 250 rules that don't align with any other organization, I'm pretty much stuck with their series. I don't have any plans to race it in CCS, CMRA, or WERA anyway. I have too many extra curricular activities as it is now, so the 5 or 6 MCRA weekends will have to suffice.

Originally Posted by Greenlawnracing

True, but you make a trip to CMRA or CCS which are in your backyard (ok, more like left field) and you won't be legal in some classes.

[DCMoney]

Originally Posted by Mark Cook

I realize that, but since MCRA decided to have their own 250 rules that don't align with any other organization, I'm pretty much stuck with their series. I don't have any plans to race it in CCS, CMRA, or WERA anyway. I have too many extra curricular activities as it is now, so the 7 or 8 MCRA weekends will have to suffice.

Fixed it for you!

[Mark Cook]

Originally Posted by DCMoney

Fixed it for you!

[NINJosh.]

hey mark, are those armour bodies plastics? that's what i'm using. couple questions for ya. i see there that with the upper mounted up you don't have the top fairing bracket bolted on, are you going to put that back in at any point or are you gonna go without it. i was looking at mine today, and i guess it doesn't really seem all that necessary. also, did you have trouble getting your tail section on? i was trying to get mine on and there is no way it will go over the cross member in the subframe. i don't want to force it, i feel like i'm going to break it. am i missing some trick to this? i bought the bike without the plastics so i have no idea how the stock ones fit or where they mounted up, and definitely no idea how these ones should go back on. any tips?
thanks man.

[simook]

Great build so far! Could you show more pictures of how you mounted the rear reservoir? It looks as if you have it inside the tail fairing.

[DCMoney]

Originally Posted by simook

Great build so far! Could you show more pictures of how you mounted the rear reservoir? It looks as if you have it inside the tail fairing.

Its just tygon 2375 tubing a cap and some clamps.



If your interested I've got a kit ill sell for $12 shipped.

[simook]

I see, it looked as if you still had the stock rear reservoir attached. I need to rear over the rules again and see if I can do away with the stock reservoir.

[cbinker]

looking good, wish i had the space to work on my 250r like that.

[Aodrn]

Ok, school me on the advantage of removing the resevoir. Is the tubing that much lighter?

[DCMoney]

Originally Posted by Aodrn

Ok, school me on the advantage of removing the resevoir. Is the tubing that much lighter?

I didn't do it for the weight savings, with my rear sets and riser plates the stock hose was rubbing on the rear wheel wearing a hole in the hose protective liner.

Plus it looks better.

[Aodrn]

Form and function. I like it.

[Mark Cook]

The reservoir removal for me, is simplicity and weight reduction/cleanup.
Anything that I can get away with eliminating goes in the trash can.
It all ads up.
Mark

[Mark Cook]

Josh,
This was just a cheap set off of ebay.
I don't have an upper fairing bracket fabbed up yet, but I will be making an aluminum one to hold the upper in place. I think even though it's pretty solid as it is, once you get up to speed it will need support.
The tail is a bit of a PITA to get on, but it will go. Just had to figure out the way to make it fit. Patience.

Originally Posted by NINJosh.

hey mark, are those armour bodies plastics? that's what i'm using. couple questions for ya. i see there that with the upper mounted up you don't have the top fairing bracket bolted on, are you going to put that back in at any point or are you gonna go without it. i was looking at mine today, and i guess it doesn't really seem all that necessary. also, did you have trouble getting your tail section on? i was trying to get mine on and there is no way it will go over the cross member in the subframe. i don't want to force it, i feel like i'm going to break it. am i missing some trick to this? i bought the bike without the plastics so i have no idea how the stock ones fit or where they mounted up, and definitely no idea how these ones should go back on. any tips?
thanks man.

[Mark Cook]

OK, I've skipped a bunch of steps but if you're on the FB you can see progress there.
https://www.facebook.com/mark.cook1/...8480085&type=3
I made the folder public, so you should be able to see the photos.

A few more things to do, and I'll be relatively satisfied with it.
Made 35hp on the dyno. Not too shabby.

[bitaria]

Originally Posted by Mark Cook

Made 35hp on the dyno. Not too shabby.

35hp is pretty high for a Ninja 250. Obviously depends on the dyno, conditions at the time etc., but seems that ~31-32hp is more inline with "supersport" build on pump gas.

Do you mind sharing any power related mods? (airbox, oil weight, jetting)