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Old January 3rd, 2019, 08:26 AM   #1
SpotTheDogg
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A ZZR500R?

Hi again guys, I haven't checked in in over a year but I have news! You may remember Paul's ZZR250-GP build from a couple years back, well I have inspired him to build a new Thunder and Sportsman Class play toy.

We bought another ZZR 250 for the frame and stuffed a fresh Ninja 500R race engine in it. It will be running a Ninja 600R aluminum swingarm, a FOX Twin Clicker shock, 2004 ZX-6R forks and a lot of the goodies we developed for the previous ZZR250GP build. Wheels will be SV650 rear and GS500 front. We found a nice old Muzzy race pipe for it as well!

We started it on Friday and got most of the big issues dealt with already, we had a welded aluminum double core rad that was too big and had outlets that were too small. We cut an inch off the bottom and re-welded it and then turned some new inlet/outlets pipes on the lathe and welded them in! Engine fits good, as does the swingarm but we will look at the current weight distribution before deciding where all the parts will go.

These are the all-new engine mounts welded in, we also scrapped the rubber mounts in the engine and made solid aluminum ones.















The Ninja600R swingarm and FOX shock, this was very nearly a bolt in swap!


Last futzed with by SpotTheDogg; January 3rd, 2019 at 02:30 PM.
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Old January 3rd, 2019, 08:43 AM   #2
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Looking good
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Old January 3rd, 2019, 09:38 AM   #3
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Old January 4th, 2019, 12:46 AM   #4
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Amazing fab skillz!!

I'm looking at doing something similar with EX500 engine. Except stuffing it into ZXR250 frame for steeper head angle.

Which tank are you using?
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Old January 4th, 2019, 05:59 AM   #5
SpotTheDogg
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Thanks, I can’t take much credit, that’s all Paul. So, the tank will be the ZZR 250 tank
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Old January 10th, 2019, 07:58 AM   #6
SpotTheDogg
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pics

Here is a few update photos, solving small logistical issues in the evenings so one thing at a time.

Built a new subframe, fairly easy as we now have a jig for this. Also, made to order if you want one at $275 CAD. We also sell a upper fairing support to be used with the TYGA RGV250 bodywork for $250 and a Ninja300 upper fairing support in aluminum for $250.





We have eliminated the thermostat housing and under tank rad cap, this is a simple splitter to bring coolant to the head.



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Old January 15th, 2019, 01:48 PM   #7
SpotTheDogg
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A few updates, things slowing down as time for solutions and custom parts takes extra thinking.



The forks get custom triples to narrow the spread, we needed to raise the chassis a bit for ground clearance. Forks are to the top and custom dogbones took care of that.



You can see the modified radiator and the extended filler neck, eliminating the stock rad cap/thermostat housing meant the cap needed to be made the highest point.



We will need to do some figuring on having the chain clear the swingarm, but it may be fine with the larger rear sprocket. That is only a 41T and we will probably put a 46T on it. If need be we may even consider a 17/48T, but hopefully not.

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Old January 16th, 2019, 06:03 AM   #8
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Old January 16th, 2019, 10:36 AM   #9
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Pretty awesome!
What does ZZR frame weigh anyway?
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Old January 16th, 2019, 09:36 PM   #10
SpotTheDogg
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Quote:
Originally Posted by DannoXYZ View Post
Pretty awesome!
What does ZZR frame weigh anyway?
We didnít actually weigh it, will try to remember when itís all torn down for paint.
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Old January 16th, 2019, 09:50 PM   #11
DannoXYZ
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Quote:
Originally Posted by SpotTheDogg View Post
We didnít actually weigh it, will try to remember when itís all torn down for paint.
Thanks!

I recall someone saying it was lighter than ex250 steel frame, but i don't know by how much. I may just scrap steel frame for my ex350rz project.
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Old January 17th, 2019, 05:52 AM   #12
Mohawk
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From this thread https://www.ninjette.org/forums/showthread.php?t=291448

>>>
250R Frame - 35.6
ZZR Frame - 20.6 (w/o subframe) or 9.3Kg
250R Swingarm - 13.2
K1 Swingarm - 8.0

And for the forks, tubes only no triples, axles, etc

250R forks - 12.8
ZX6R forks - 14.8

This is on my NASA approved ultra accurate bathroom scale with an amazing resolution of 0.2lbs....YMMV but good for comparison.
<<<

Lets hope those scales were somewhere near accurate
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Old January 17th, 2019, 09:53 AM   #13
DannoXYZ
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Ah, thank you!
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Old January 21st, 2019, 08:14 AM   #14
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I feel like I need one of these in my life LOL
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