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Old April 24th, 2015, 08:49 PM   #41
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This build pushed me over the edge to cafe my ninjette,metricmoto's Maya:
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Old April 26th, 2015, 06:25 PM   #42
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Final fit on swinger done, I put the swivel end into a toaster over to expand the swinger and then fit the brass bushing, then put the swinger back into the oven after I trimmed the bushings to fit to expand them and bang the smaller bearings in. Fit is good.

I had to get some bead sealer to get a good tire seal, so that is done. I chose the tire heights to be as wide as possible and still match height-wise front to rear. Now have to balance and polish wheels. Waiting on new brake caliper seals and also muffler has been selected to be ordered.

As to the tank, I am playing around with this gutter guard material to fill in the tank indentations where the fairing used to go- it's going to be painted flat black. I have a few more ideas if I change my mind.

Some bike pron
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File Type: jpg 20150426_210556[1].jpg (147.9 KB, 15 views)
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Old May 4th, 2015, 08:29 AM   #43
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No more pics, rebuilt the calipers last night ordered up the muffler.
Plan is to have it rideable by end of the week, not street legal but rideable around my cul de sac. So brakes, forks, balanced wheels going on tonight.

Will work on mounting headlight and gauges later this week.
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Old May 4th, 2015, 08:58 AM   #44
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I would have loved to do a front end swap, I just to heavy for a stock 250 setup. but I didn't know about all those all balls swap kits or I would have..... Next winter.... Or maybey I'll need more power by then, this one is fun for now.
My plan is an EX500 motor swap once I've mastered the hamster power.
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Old May 4th, 2015, 06:01 PM   #45
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Looking Good

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No more pics, rebuilt the calipers last night ordered up the muffler.
Plan is to have it rideable by end of the week, not street legal but rideable around my cul de sac. So brakes, forks, balanced wheels going on tonight.

Will work on mounting headlight and gauges later this week.
I like the build so far! Nice work!
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Old May 7th, 2015, 12:56 AM   #46
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Old May 9th, 2015, 01:36 PM   #47
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Finally a roller. Tomorrow finalizing the seat so it can get upholstered, brake lines and bleeding. Should be a runner after checking all bolts. Muffler should be here Monday.
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Old May 10th, 2015, 12:17 PM   #48
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Thumbs up

Do not know if I had told you yet but this bike is awesome. Your creativity is awesome. Now I need to learn how to go this far. Awesome build.
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Old May 21st, 2015, 05:12 AM   #49
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apparently I need to pay more attention to the old gen section of the forum. Awesome work
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Old May 21st, 2015, 07:49 AM   #50
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I was also looking into running ex500 later model wheels since they are so cheap. Was afraid of spacing though. I think I am just going to put out the cash for the lighter new wheels. Last thing I need is the wheels. Never tried centering a wheel that wasn't original on the swingarm so not sure how it is done. Was the front end and rear cheaper than doing the newgen swap?
I'm late to this discussion, but I wanted to point out that the 500 wheels match up with the NewGen wheels. The pivot point of the 500's swingarm is 7mm wider than the NewGen's, and the way the speedo drive and front wheel work together is slightly different. But overall, you can swap the front and rear wheels between the two without any real issues, just a couple other little OEM parts. Myself and at least one other guy have the NewGen Vrossi wheels on our 500s.
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Old May 21st, 2015, 07:58 AM   #51
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Thanks for all the feedback guys!
I am going to mount the headlight tod
ay, mount muffler bleed front brakes- back ones already bled. Maybe even finish the wiring for the gauge...
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Old May 26th, 2015, 02:35 PM   #52
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Is the Ninja 600 swing arm lighter than the stock one?

Cheers,

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Old May 26th, 2015, 03:45 PM   #53
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Is the Ninja 600 swing arm lighter than the stock one?

Cheers,

Zach
Yes iirc 6lbs vs 11lbs
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Old June 3rd, 2015, 06:42 AM   #54
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Life keeps getting in the way, no progress to report other than ordered up some nice mirrors- but wrong ones sent by seller, may keep em anyways.

Tonight gonna make it a runner no matter what!!!
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Old June 4th, 2015, 07:31 AM   #55
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Life keeps getting in the way, no progress to report other than ordered up some nice mirrors- but wrong ones sent by seller, may keep em anyways.

Tonight gonna make it a runner no matter what!!!
Called it quits at 1230am, not a runner!

Rejetted carbs, played with gauges, speedo magnets done, figured mounting for speed sensor.
Mounted radial cylinder reservoir
Adjusted clip ons.
Muffler was previously mounted.

Going to make seat pad tonight and finalize gauge mount, speedo sensor mount and gauge wiring and mount carbs. Finalising main wiring and headlight this weekend. Stuff takes waaay longer than I expect.
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Old June 18th, 2015, 01:24 PM   #56
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Boohoo! Not much got done. Started playin with speedo sensor mount. Rejetted carbs. Started battery mount. Going on vacation. Brb...
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Old July 10th, 2015, 03:17 PM   #57
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Boohoo! Not much got done. Started playin with speedo sensor mount. Rejetted carbs. Started battery mount. Going on vacation. Brb...
Are you back?
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Old July 10th, 2015, 04:57 PM   #58
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Are you back?
tomorrow for sure!
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Old July 11th, 2015, 12:06 AM   #59
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tomorrow for sure!
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Old July 20th, 2015, 03:12 PM   #60
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what are you using for your coolant
tank? how did you set that up?
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Old August 3rd, 2015, 04:38 PM   #61
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Old August 23rd, 2015, 08:45 PM   #62
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Ahem,no matter what never happened way back when.

Sooo, picked up some slack. Trying to bleed front brakes, left brake
lever tied to try bleed- no pressure.

Delegated the seat upholstery cushion to my 15 year old daughter- used harbor freight foam floor tile, I will add softer foam on top, semi finished, you can see the muffler also:

Mounted battery, mounted carbs and installed the throtle cables.
I made a small L shaped tray and bolted it to using 2 holes under tank and
right above the carbs, mounting the fuse block on top of the battery.

Next do the coolant can, finalize seat mount brake light and headlight.
I tried to rotate these pics but, here they are nonetheless.
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File Type: jpg 20150823_205555.jpg (121.7 KB, 34 views)
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Old August 29th, 2015, 09:43 PM   #63
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Dope!! This Project is coming together nicely! any updates? i've been stalking this thread for awhile
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Old January 30th, 2016, 04:23 PM   #64
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Dope!! This Project is coming together nicely! any updates? i've been stalking this thread for awhile
Yess!!!
I charged the battery since then.
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Old January 30th, 2016, 05:48 PM   #65
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U sticking with the stock wheels, or have u thought of spoke wheels?
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Old January 31st, 2016, 11:22 AM   #66
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Dope!! This Project is coming together nicely! any updates? i've been stalking this thread for awhile
Thanks. I have to get to it. So close to the finish line. Gonna have to neglect other stuff to work on this.
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Old January 31st, 2016, 11:29 AM   #67
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U sticking with the stock wheels, or have u thought of spoke wheels?
I am using the 600 wheels forks, front rear brakes and swing arm.
250 rear sprocket and 250 chain and rear master cylinder.
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Old February 6th, 2016, 07:34 PM   #68
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Controls done
Figured out the headlight mount and rearview mirror.
Still need to finish up the seat. Thinking about a single seat with a hump.
Still need to mount ignition switch and coolant over flow and rear light. Headlight needs wiring and has built in front signals. Getting there.
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File Type: jpg IMG_20160206_212214317.jpg (127.1 KB, 21 views)
File Type: jpg IMG_20160206_212248156.jpg (106.2 KB, 21 views)
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Old February 6th, 2016, 10:39 PM   #69
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Excited to see how you do the overflow tank. Keep up the good work!
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Old February 16th, 2016, 07:55 PM   #70
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Sweet Build!!
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Old February 20th, 2016, 06:32 AM   #71
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Well Done so far. I'll post pics of my build soon, but not nearly as inventive as yours.
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Old March 4th, 2016, 09:42 AM   #72
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Well Done so far. I'll post pics of my build soon, but not nearly as inventive as yours.
Get to it!

I am scrapping the homemade seat and going a different route. Plan is to deal with the tank while I wait for the seat and the lower fairing as well. Also finish up the wiring of the speedo and front/rear light.
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Old March 16th, 2016, 07:01 PM   #73
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Measured my non-stock rear dogbone. 5 7/8 long. Stock is 5.5 (not 6.5 ) so my bike is lower than stock (not higher) which should work out with the gxsr shock and shorter rear tire.

Quote:
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http://faq.ninja250.org/wiki/Are_the..._Disadvantages

Sure about that? Your avatar says you have a pregen, no?
shoot! I read stock was 6.5 on the interwebs!

Guess gotta figure this out. Looks Like it is a one inch drop link. @@@ actually it's a 1.25 lowering link from diamond.
Thanks



Riding it will tell where I end up. I hope to finish the headlight wiring and signals this coming weekend. Haven't really messed around
with the rest of it.
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Old March 21st, 2016, 02:27 PM   #74
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New seat came in.

First is the new seat as is- is seems way too long.
The second is sort of the shortest I would chop, I will probably shoot for something in between. I also have to widen the front of the seat "rails"(the sides), so it sits flush to the frame. Between the seat and tank will be a custom fiberglass filler piece of some sort.
You can see the the coolant overflow tank setup below the radiator on the left side.
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File Type: jpg new seat.jpg (117.3 KB, 201 views)
File Type: jpg chopped seat.jpg (129.9 KB, 30 views)
File Type: jpg drop side.jpg (124.3 KB, 31 views)
File Type: jpg IMG_20160321_165623802.jpg (158.5 KB, 25 views)
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Old March 21st, 2016, 04:56 PM   #75
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Started modding the seat, the front of it is too narrow. The idea is to cut the seat tray and put some aluminum plate under to push out the sides so it sits flush. I will add some padding to the new gap in the foam..
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Old March 21st, 2016, 06:28 PM   #76
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Where will the battery be?
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Old March 21st, 2016, 06:48 PM   #77
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Where will the battery be?
post 62 , it is tucked under the tank and right above the carbs, I made an aluminum bracket for it. The fuse box will live under the seat pan. as will most electric stuff.
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Old March 21st, 2016, 06:59 PM   #78
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post 62 , it is tucked under the tank and right above the carbs, I made an aluminum bracket for it. The fuse box will live under the seat pan. as will most electric stuff.
I had no idea there was that much room above the carbs, I moved my battery as low and back as I could while still clearing my piggyback shock resovior. I need to get a second scale to I can measure my weight balance.
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Old March 28th, 2016, 06:58 PM   #79
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post 62 , it is tucked under the tank and right above the carbs, I made an aluminum bracket for it. The fuse box will live under the seat pan. as will most electric stuff.
WOW this is awesome.. One day im going to have to try that one out.. Great spot. There was one build on here that I remember trying to figure out where he put the battery that must have been it. Mind if I use that idea one day? lol
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Old April 29th, 2016, 04:02 PM   #80
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Put some gas in it and fired it up it's friggin LOUD. Pretty much done except for some wiring and I have bled and bled and bled that master, can't get rid of that mushy brake feel. Ordered a rebuild kit and should be here Sunday- Amazon Prime Shipping. Lets see if its the correct one .
Gonna keep pushing this til it's done.
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