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Old 05-21-2011, 07:14 PM   #1
RideDualSport.com OP
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1984 Ninja 900 - Resurrection of the Assassin!



World Press Release 1984 Laguna Seca

Back in the 1980's my brother and I did some amateur road racing in the Pacific Northwest. One of the bikes we built was our Battle of the Twins winning Kawasaki EX500. This bike lead to the next build... a 900 Ninja.



A bit after the EX500, my brother moved to Texas and worked at Quadracycle where they built up the mighty Ninja 900. The motor has a big-bore kit, ported head, flat slide carbs, race pipe and a fortified tranny and clutch.The result was 120 hp at the rear wheel, and it hit 160 mph at red-line in top gear.



The bike shortly after it was built.



After about 15,000 miles of riding, the bike suffered a minor accident, and was put in storage. The last time is ran was about 1989. Our goal is to revive it by giving it a cosmetic restoration, suspension re-build and tune up. Ebay and BikeBandit have proven to be a good source for parts. Here it is as delivered to the Man Cave, a few months ago.



It needs new tires, carb rebuild, suspension bearings lubed, valves adjusted, new fork bushings, fairing replaced, and lot of misc. refurbishment.



I started with the Performance Machine wheels and disks, by removing disks and polishing the wheels.



I removed the disks in order to polish the wheels:
Before:


After!
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Old 05-22-2011, 06:36 AM   #2
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So, the front and rear suspension are removed for cleaning, inspection and perhaps new bearings in the rear linkage.
The swing arm nuts were pretty locked in with corrosion, and took some heat and penetrating oil to break loose.


I also polished and sprayed clear coat on the disk carriers. I may be clear-coating the wheels as well.


I polished the foot peg hangers and repainted the black inlays.
It's kind of a slow process, but low pressure and fun!
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Old 05-22-2011, 06:39 AM   #3
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I painted the upper and lower triple clamps, handlebars, bar end weights, and polished the muffler and the fasteners for the disc brakes.
Next up is cleaning, inspecting and re-bushing the rear suspension linkage.



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Old 05-22-2011, 06:40 AM   #4
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Ok, I installed new needle bearings in the swing arm and shock linkages.
All the parts painted nicely with Duplicolor brake caliper paint - very durable!
Next up, assembling the rear suspension!



Fox Twin-Clicker in all its totally rad rock and roll colors!


I polished the wheels and clear coated them with Eastwoods wheel paint.
New Pirelli Sport Demons round out the package.


No cush-drive, the sprocket bolts directly to the hub. This bike is gonna kick butt.
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Old 05-30-2011, 03:24 PM   #5
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Originally Posted by RideDualSport.com View Post
Ok, I installed new needle bearings in the swing arm and shock linkages.
All the parts painted nicely with Duplicolor brake caliper paint - very durable!
Next up, assembling the rear suspension!



Fox Twin-Clicker in all its totally rad rock and roll colors!


I polished the wheels and clear coated them with Eastwoods wheel paint.
New Pirelli Sport Demons round out the package.


No cush-drive, the sprocket bolts directly to the hub. This bike is gonna kick butt.
great work. great job. and great thread. it's scary to think 80's bikes are starting to qualify as old but on the bright side it appears to be a veritable buyers market.

keep it going. awesome effort.
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Old 05-30-2011, 06:07 PM   #6
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Thank you Natchflug and FYR, glad you are enjoying it! I think the big appeal to rejuvenating the 900 Ninja, is that my brother and I are approaching it from a more mature and experienced viewpoint now that we are 50 years old. There is also a lot of nostalgia and perhaps second childhood involved too.
We raced Ninjas in the 1980s and back then you pretty much threw the bike away after it was beat to death on the track. Now, we are pampering this 84 Ninja, and fixing various details that we did not care about, and trying to make it an even better bike than it used to be.
Cheers!
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Old 05-22-2011, 06:47 AM   #7
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1984 Ninja 900

I had a 1984 that I bought new sold it about 7 years ago. I had a Yoshirmura piston kit, cams and spring set, 4 into1 pipe. Flat slide carbs , head and bottom end blueprinted by Klaus Speed Works in Houston. Looking forward to your resurrection of the 900.
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Old 05-22-2011, 08:22 AM   #8
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Wow, ldDave. I am sure that was a heck of a sweet bike. I am sure the motor was incredible. Our Ninja motor was also blue-printed, tranny gears undercut and heads ported, by a top drag race engine builder (the owner of Quadracycle) who used to compete against the likes of Russ Collins.
I'll be re-building the front forks next. They already have race-tech goldvalves, but the fork bushings are shot.
We found a more complete list of the engine mods:

- Heavy duty cyl studs
- Heavier valve springs
- Deburred head casting
- Magnafluxed and race-cut transmission
- Balance, bore, hone, fit pistons
- Balance, polish crank
- Polish, shot peen, balance rods
- Billet clutch hub
- New clutch plates
- Race ported head, radius valve job
- New valves, guides, seals
- Wiseco 972cc piston kit
- Mikuni RS36 D8-K race carbs
- New chain tensioner, alternator chain,starter chain
- D&D Show and Go header
- Fox Race Shock
The bike pumps out 110 hp at the rear wheel.

Cheers!
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Old 05-22-2011, 08:42 AM   #9
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Looks great and it feels all so good whan all those small bits come together as a complete unit!!
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Old 05-22-2011, 10:30 AM   #10
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Thank you Crawler, yes it is very satisfying to see the bits and pieces coming together. Although, there are times when I question my sanity. Like polishing and cleaning the heads of various bolts, cleaning the inside of the chain guard, even though no one will ever see it. I guess it's an integrity thing...the feeling of getting it right.
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Old 06-30-2011, 06:32 PM   #11
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This evening I rebuilt the forks with new fork bushings, seals, race-tech goldvalves and specially machined blocks that replace the funky anti-dive system. This weekend I should have the entire front end assembled with the front tire installed.





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Old 07-16-2011, 01:45 PM   #12
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Ok, so I cleaned the Mikuni RS Series Radial Flat Slide and installed new pilot jets, main jets and cleaned the float needles. I also put coolant in the bike, cranked the motor over and checked for spark and installed new plugs.


The Mikuni RS Series Carburetors were designed and built in response to the needs of the world's top motorcycle road race and drag race teams. They required carburetors which would satisfy the precise fuel metering demands and high flow volume required by highly modified race engines. And yet, also provide the smooth, controllable throttle response that is needed by any rider pushing his motorcycle to its limits on the race track and under high performance use.

The carburetors need to meter fuel correctly under a wide range of atmospheric conditions and engine tuning modifications while being easily accessible for trackside tuning changes which need to be made quickly.

Designed for in-line four cylinder performance motorcycle applications, the Mikuni RS Series Radial Flat Slide Carburetors offer superior horsepower gains with their maximum flowing smoothbore induction tract and radial flat slide design. An adjustable accelerator pump system helps to provide instant throttle response, particularly in the lower RPM range.

The RS series Carburetors feature a compact design which is 25% lighter than other performance carburetors, offers quick needle jet adjustment, and uses readily available standard Mikuni jets.


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Old 07-21-2011, 04:35 PM   #13
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The new Corbin gunfighter came in today! In leather too!

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Old 07-22-2011, 09:26 AM   #14
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Oh man...looking at the close up photo's brings back memories of working on mine. I liked the Corbin on my 900's...just looks right.



I also enjoyed my 85 FJ1100...awesome motor

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Old 07-23-2011, 04:46 PM   #15
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that's beautiful

love the 80's superbikes!








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