Lightening her up

[Chicagobob]

My daughter (she's 17) and I found this '06 for $1,500 and, after tuning it up and adding new tires, thought we could lighten it up considerably with some of the parts I had lying around from other projects. Turns out the rear bodywork weighs about 9 lbs and the front fairing, headlight and instruments weigh 17 lbs, so we got to work. Our progress so far, with aftermarket 7" headlight, aluminum turn signals, Trail Tech Vapor speedo/tach, and Amazon.com mirrors (total weight, 3.5 lb), so we've shaved off about 14 lb, and hope to lose another 8 or 9 soon. As soon as we figure out what to do with the rear end without all the rest of the bodywork, off it comes. Our progress so far:




One note: We discovered that the stock gauges use the same rubber indicator light sockets as Trail Tech's Vapor dashboard surround, so all you have to do is pull them out of the stock gauge housing and shove them into the back of the Vapor surround.

[ryan.chin]

Looks great. What's the reason you want to lighten the bike up?

[Chicagobob]

It weighed about 300lbs stock, but seemed topheavy nonetheless, and she has to pass the parking lot "crawl and wobble" DMV exam with it, and we'd like to make the bike as flickable as possible. I know 4.8 gallons of fuel adds a lot to it, but we figured we could improve matters and, at the same time, create something unique (I know this look isn't unique among Ninjette aficionados, but I've never seen another naked Ninja 250 other than on message boards) and ditch the 80s styling. We think we can lose 24-25 lbs, most of it above the rider's waist.

[Motofool]

I like it !

No much more that you can do, other than removing the center stand and keeping the tank half full.

[ryan.chin]

Removing the rear fender, after market exhausts typically weigh less, remove passenger pegs... That's about all I could figure. How tall is your daughter? As long as she can really place two feet on the ground comfortably, she should be okay.

[Chicagobob]

Next off is the rear bodywork. With its cast metal grab handle and huge plastic fender, it is heavy, and it is high. We've got a lightweight LED taillight and license mount, so we just have to fabricate a mount for it that provides sufficient rain protection and looks decent. We'll try to trim the side covers so we can cover some of the electrics and the coolant tank. Like this:



Later note: Here's how it's turned out so far. I started another thread about the rear end work.

[ryan.chin]

Originally Posted by Chicagobob

Next off is the rear bodywork. With its cast metal grab handle and huge plastic fender, it is heavy, and it is high. We've got a lightweight LED taillight and license mount, so we just have to fabricate a mount for it that provides sufficient rain protection and looks decent. We'll try to trim the side covers so we can cover some of the electrics and the coolant tank. Like this:

Please don't make me jealous of a 17 year old girls bike. Haha just kidding, looks great!

[alex.s]

sweet bike. maybe bob the tail completely, and replace it with a single-seat. you would want a rear hugger with no tail... then have one of those chopper style license plate mounts that connect behind the swingarm and wrap around the back of the wheel. that would look great. and its nice and low.

[choneofakind]

Heyyyyyy, that's Jono's bike!

Originally Posted by Chicagobob

[rabies]

itd easy to cut off the tail. my bike is pretty light.
i have no turn signals
no rear pegs.
2 to 1 exhause with overpriced dirtbike sounding areap exhaust
ditched headlight and bracket for dirtbike headlight

[alex.s]

i wanted to join the club...

[lowdown112]

Originally Posted by rabies

itd easy to cut off the tail. my bike is pretty light.
i have no turn signals
no rear pegs.
2 to 1 exhause with overpriced dirtbike sounding areap exhaust
ditched headlight and bracket for dirtbike headlight

Even tho its a small pic this bike looks good like a little tank and LOVE the yellow ninja!

[lowdown112]

At least id get a fender eliminator and take the grab bar off the back. that thing is solid metal.

[Chicagobob]

Originally Posted by lowdown112

At least id get a fender eliminator and take the grab bar off the back. that thing is solid metal.

Yeah, that's next. We temporarily removed the rear bodywork, taillight, grab handle, fender and turn signals, and found that they weigh 8.5 lb.. Since most of that is up behind the rider's butt, we're going to ditch it ASAP.

We'll probably cut a couple of inches off the end of the frame and fab a mudguard and license/taillight mount. I like how this guy did it, except for the antique Ford taillight:


I also like how he mounted the stock speedo and tach, apparently in tin camping cups. I guess that goes with his military theme.

[Chicagobob]

Originally Posted by alex.s

i wanted to join the club...

Nice! Like the tailpieces.

[Monkeytofu]

If you can teach your daughter to wheelie everywhere you should be able to remove most of the front end for a considerable weight reduction.

[StephenA]

i'm lovin it, subb'd

[iplante]

Originally Posted by Chicagobob

Yeah, that's next. We temporarily removed the rear bodywork, taillight, grab handle, fender and turn signals, and found that they weigh 8.5 lb.. Since most of that is up behind the rider's butt, we're going to ditch it ASAP.

We'll probably cut a couple of inches off the end of the frame and fab a mudguard and license/taillight mount. I like how this guy did it, except for the antique Ford taillight:


I also like how he mounted the stock speedo and tach, apparently in tin camping cups. I guess that goes with his military theme.

this is the first naked Ninjette that I actually think looks cool. Good find

[kg4kpg]

Originally Posted by iplante

this is the first naked Ninjette that I actually think looks cool. Good find

Pretty sharp, I'd like to we a complete walk-around of the commando ninjette.

[Chicagobob]

Here's how mine looks now. I've still got a few details to work out, but it's rideable and a blast.

[kg4kpg]

I like it, very clean and still sporty. I want to go naked but just can't seem to get started. I've been thinking about the exposed bolt holes on the side of the tank, I wonder how easy it would be to do some fiberglass panels to bring the contour forward and wrap into the front of the tank or ever over the radiator fill hose to hide it without becoming a fairing again? I also like how you opened up the rear end by moving the electrical components, did you have any issues relocating them?

[Chicagobob]

Originally Posted by kg4kpg

I like it, very clean and still sporty. I want to go naked but just can't seem to get started. I've been thinking about the exposed bolt holes on the side of the tank, I wonder how easy it would be to do some fiberglass panels to bring the contour forward and wrap into the front of the tank or ever over the radiator fill hose to hide it without becoming a fairing again? I also like how you opened up the rear end by moving the electrical components, did you have any issues relocating them?

I've seen others smooth the fairing mounts over with bondo and repaint the tank, but they don't bother me that much. You could also switch to a vintage tank and cafe racer seat for a more traditional appearance. Check out what this guy did:

Pretty cool, but he had to sacrifice his fairing, and I hope to sell mine.

The electrical relocation actually took more time than the rest of the work, but only because I wanted to retain the stock rear inner fender and seat latch. If I eliminated them, I'd have room for all that under the seat. As it is, I placed the ECU under the tank (where I hope it doesn't get too warm) and the rectifier on the left side of airbox, in front of the coolant tank. I had to lengthen the taillight wires, because they now have to reach from in front of the coolant tank. Otherwise, no problems.

[alex.s]

oh my god that bike looks sexy as fuu


well... the seat needs to be redone and i would be sketched not having the under support for the seat frame, but props to that bike

[Rollingmenace]

I agree w ^^^^^ that bike looks bada** I bet you couLd easily take another tube and run it parallel to top seat tube and radius it down to original lower mounting point and it would look great and be considerably stronger

Any further info on that bike ? Link?

And BTW bob the yellow ninja is looking Sweet as well

[Chicagobob]

Originally Posted by Rollingmenace

I agree w ^^^^^ that bike looks bada** I bet you couLd easily take another tube and run it parallel to top seat tube and radius it down to original lower mounting point and it would look great and be considerably stronger

Any further info on that bike ? Link?

And BTW bob the yellow ninja is looking Sweet as well

That one's from CustomFighters.com, at http://www.customfighters.com/forums...ad.php?t=27978.
The builder said that he was abandoning the project, and never finished it.

[rabies]

Originally Posted by Chicagobob

i actualy copied this guy.
i plan on after getting my new welder today cutting the rest of the frame out and welding a lateral support unlike he did

photo hosting sites

[Rollingmenace]

Yeah rabies I've been watching your build as well .. I really like the look of the rear cowl and the dirt bike fender thing on the red and white one..The lines are super cool and it resembles a super motad bike.. I'm gonna try to dig up info on it..... Sorry for the hijack

[alex.s]

rabies you should ditch the mask for an oldschool sealed beam style headlamp housing. maybe its just me because i used to have that acerbis headlamp on my streetfighter before i got tired of it and threw it away

[Chicagobob]

I removed a little more - the seat latch mechanism and its frame plates, and the bungee clip mounts. The seat now is held on by a wingnut through the rear crossmember. Shaved off a little more weight this way, and it looks pretty good, too.

Sorry about my thumb over the top of the pic - This was one of the first photos I took with my new iPhone.

[Alex]

I want hi-res pics of that bike. It looks fantastic.

[k-os]

Just saw this in my new Cycle World.



Big Version

[Alex]

Nice!

[Eagle981]

Originally Posted by Chicagobob

I removed a little more - the seat latch mechanism and its frame plates, and the bungee clip mounts. The seat now is held on by a wingnut through the rear crossmember.

Bob, any chance of getting some pics of how the seat mounts now, been looking for alternative ways to mount the seat

[Chicagobob]

I mounted the seat using just a bolt and wingnut. I've used this method on other bikes. It's mechanically secure and theft-resistant, since most people can't easily see under the fender (It'll either be too dark, or the sun will be in their eyes if they try to look up there), and so can't figure out how to remove the seat (unless I reveal the secret on the internet, hmm . . .).

The Ninja seat already mounts very securely, since it has a tab under the fuel tank and locator holes in the rear frame crossmember, so the only other thing that's needed is a way to hold the thing down. The stock latch mechanism works well, but was unsightly and no longer theft-resistant once I had removed all the bodywork, since it was fully visible. It and its frame tabs and lock also weigh about 2.5 lbs.

Here's the new "fender" I made after I removed the stock rear inner fender. It's simply a sheet of aluminum cut and bent to fit the countour of the existing frame crossmember, and bolted to the frame with self-tapping sheet metal screws. This part also holds the tail light and license. It could also have held the turn signals, if I had had more foresight. It's spray-painted black:


Here you can see the hole for the seat bolt:


I cut a couple of holes in the seat bottom and added this brass bolt and nut, which runs through the hole in the aluminum sheet:


Here's the wingnut that holds it all together from under the fender:


Here's a view from underneath, with the wingnut in place. This would also work with a c-nut attached to the seat bottom and a thumb-bolt inserted up through the rear fender, but then you have to fish around for to find the nut each time you attach the seat.


Because I removed the seat latch and frame tabs, the rear of the frame has a cleaner look. I installed the helmet lock in front of the right rear turn signal:

[CZroe]

Originally Posted by k-os

Just saw this in my new Cycle World.



Big Version

I wonder why some guy from OH is complaining about Atlanta traffic.

[Z-Trob]

ugh you're making me jealous. these bikes cut the corners up so well the only thing better is a bobbed, minimalist version. but my bike must remain covered up, as a friend just starting out riding this season wants to purchase it from me... oh well, maybe ill just have to find a neglected ninja to cut up... i mean revive


dont know if you thought about these but;
lithium battery, clip-ons, and a full exhaust would lose 20+ lbs easy. those stock cans are heavy, as well as the headers! with led signals and tail light you wont need a big battery, a 4 cell could probably do it. your bike is so light you could just push start it if the battery cant start it.

[Chicagobob]

Yeah, we thought of all that, but we didn't want to spend more money.

[eulark]

Hey Chicago,

I havent seen that vapor unit before and i like the digital style better than my analog. Any pics of the install and any idea if it would fit with a fairing in place? I take it the speedo and tach are both at least as reliable as the original analog one?

Again, this bike looks sweet.

[Chicagobob]

It'll fit with a fairing. I actually installed it while the fairing was still on the bike (but I removed the stock instruments first). It's about 4" wide and only a few ounces. Installation info is all set out at trailtech.net.

Speedo is better than stock, because it's adjustable. Tach is jumpy unless you use Trail Tech's resistor wire (about $15), but it's accurate. Clock, timers, temp gauge, and odometers are useful. Trail tech sells a number of different computers in similar styles, but the Vapor seems to be the most useful for the street.

Check out their mounting instructions at trailtech.net.

[bbjminardo]

Originally Posted by Chicagobob

I removed a little more - the seat latch mechanism and its frame plates, and the bungee clip mounts. The seat now is held on by a wingnut through the rear crossmember. Shaved off a little more weight this way, and it looks pretty good, too.

Sorry about my thumb over the top of the pic - This was one of the first photos I took with my new iPhone.

Absolutely beautiful bike, Deffiently gonna be a project bike for me when one pops up on craigslist. Hoping to get a beat up one so itll be super cheap and since ill be removing the fairings anyways! GREAT WORK!