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Old 01-23-2011, 05:05 PM   #1
dentvet OP
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Location: hunt country virginia
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Kawasaki 650 Thinja notes; parts bin build

Here are some notes regarding the rebuild of the ubiquitous Ninja 650R bike. Sanjoh and Jdrocks and others have great builds going on and i'm trying to emulate those efforts. I have posted a lot in their threads, probably creating confusion for those following along. I guess its time for me to move my clutter into its own space. Maybe this will get me to be more organized.

My bike came through the insurance auctions, apparently somebody did a 3 o'clock wheelie on it. Mostly cosmetic damage. I had no need for a sportbike but thought a dirt ninja might be interesting.

Here it is after i picked it up from woodswizard:



I stripped all the damaged plastic off, weighed it at just under 400 #. Purrs like a cat but the 2 bros is too loud.



Cleaned away the fairing stay and mounted the headlight and clocks onto the forks.




I rode it around in this configuration a bit and found it to be a pleasant bike overall. I probably should have left it like this but I have a bunch of bike parts that might work to make the bike more dirt-road capable. Maybe I could take it on fire roads, etc.

Things that make the bike not dirt-roadable:

weighs 400 pounds
has a bulbous fuel tank
bars are low and the pegs are too far back
street suspension and tires
low ground clearance

I'll try to work on some of those issues before springtime.

Front end. Street forks and 17 inch tires need an upgrade. Sanjoh used a front end off a ktm 640 so I thought i'd just do the same. I have a 400sx bike donor.



I am trying to use a YZ triple clamp wth shims to hold the 43mm WP forks. The KTM clamps are too short and sanjoh found that the top clamp hits the fuel tank at full turn. The YZ clamp solves both of these issues and has steering offset of 22.5 mm compared to the 20mm KTM figure. I'm not sure if that's good or bad.

The steering stem is going to require a shim for the upper bearing to take it to 35mm from 28. The Ninja bearings are 35/55mm units, the YZ stem takes 30 and 28mm bearings. Honda streetbike bearings are 30/55 so I will run one of those along with the shimmed upper from Kawasaki streetbikes.





Today's issue, the rear wheel:

I'm fitting a KTM cush wheel onto said thinja. Centering the wheel necessitates shimming the sprocket 15mm to the left for sprocket alignment. Here is a rough draft sprocket spacer. Is it possible to buy sprocket spacers? (I have seen rotor spacers)



A couple FYI items learned in the other threads:
KTM and Thinja share 520 chains, 20mm rear axles and 220mm rear rotors
Yamaha rear sprockets fit KTM but not vice versa

dentvet screwed with this post 01-23-2011 at 05:20 PM
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Old 01-23-2011, 05:50 PM   #2
jdrocks
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a THINJA, sounds cool.

by the looks of the old tank, i hope it wasn't certain body parts that did that.
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Old 01-24-2011, 07:17 AM   #3
Kawidad
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I'm in. I love these Ninja builds. I may give it a go in about a year from now.
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Old 01-24-2011, 12:52 PM   #4
Cortez
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Old 01-24-2011, 01:58 PM   #5
istbenz
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Subscribed! I've been following these adventure ninja threads taking notes- maybe I'll get around to making one of these too

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Old 01-25-2011, 04:49 AM   #6
sanjoh
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Hey nice color scheme



Not sure where you are on the build, I would recommend tackling one area/project at a time just to keep your sanity
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