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Old 03-23-2012, 04:21 AM   #346
ktmklx OP
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Originally Posted by ben2go View Post
I am in the south east so I never even considered those.I had one on my racing kart.They needed rebuilding frequently,but that may have been a side effect of running methanol.
I would have to agree with your methanol theory, The Mikuni sled pumps are very reliable.
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Old 05-03-2012, 09:29 PM   #347
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I have been looking at the rear end of this bike for quite some time, trying to figure out how to get a little more suspension travel from the ninja. So off came the the R1 shock spring and I checked the rear axle travel. It was a little short of 6" This number will not be the same as a stock ninjas with an R1 shock because of some other mods to the bike. The custom inner fender affects when the tire bottoms and the swing arm shock mount has been modified.



Last summer before the Montana trip, I installed a different spring on the Yamaha R1 shock. This spring did not provide the sag that the stock yamaha spring did, the seat ht was out of control. I had to do something quick, there was no time to fix this with a parts order. I decided to drop the bike by moving the rear shock mount back about 3/4". The good, the seat ht was now manageable, the bad now the tire hits the inner fender even earlier.

Before


After
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Old 05-03-2012, 09:37 PM   #348
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My solution to the suspension travel issue is to create a new inner fender that the tire will not hit and to lengthen the swing arm.

Length (1") added to the swing arm and the brake torque reaction block moved back 1". some gussets also added.

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Old 05-03-2012, 09:48 PM   #349
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The stock seat latch was retained last year, but this year it has to come off the bike. It takes up to much room in the inner fender area.


Last years inner fender went underneath the seat mount crossbar. This year's new design has the inner fender going over the seat crossbar. The crossbar is modified and the new design has a 2 piece inner fender instead of a one piece.

Last Year's



This Year's

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Old 05-03-2012, 09:54 PM   #350
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Travel measurements now.








For the math challenged that is 7 5/8" inches.


ktmklx screwed with this post 05-03-2012 at 10:11 PM
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Old 06-03-2012, 07:17 PM   #351
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Update continued, with the swing arm & inner fender modified the shock bottoms with clearance between the inner fender and the tire.

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Old 06-03-2012, 07:21 PM   #352
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The seat latch had to be modified:




The ECU was relocated to the very back of the bike.



I moved the muffler back about 5" to reduce the chance of burning a good pair of riding pants.

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Old 06-03-2012, 07:27 PM   #353
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I bought an old an old South Bend 10" lathe a few weeks ago. The first parts for the ninja, these nice little weld on stand offs for a radiator guard.







Also turned out these windscreen supports:

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Old 06-04-2012, 05:28 AM   #354
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Nice job there. If you need tooling blanks for your lathe let me know I literally have ten lifetimes worth. Free of course to a fellow builder
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Old 06-04-2012, 08:00 AM   #355
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Thats some nice work .going to make a better one for my bike but haven't made my mind up on putting the versys radiator or leaving the Ninja. So far the Ninja has word fine.
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Old 06-04-2012, 01:47 PM   #356
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I may have to add the length to the swingarm as you did, the rear suspension and lock-to-lock steering reduction are the only issues I have with my build(aside from it not being entirely finished). I bottom out the tire on the underseat way too often, pretty much any time I hit the whoops.
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Old 06-04-2012, 06:43 PM   #357
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Originally Posted by pjm204 View Post
I may have to add the length to the swingarm as you did, the rear suspension and lock-to-lock steering reduction are the only issues I have with my build(aside from it not being entirely finished). I bottom out the tire on the underseat way too often, pretty much any time I hit the whoops.
Ktm swingarm and pds shock...
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Old 06-04-2012, 07:45 PM   #358
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Nice job there. If you need tooling blanks for your lathe let me know I literally have ten lifetimes worth. Free of course to a fellow builder

Thanks for the offer. The lathe actually came with a lot of tooling, I almost shit a brick when I saw it on CL. Great price on it, and just 15 minutes away.
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Old 06-04-2012, 08:05 PM   #359
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Thats some nice work .going to make a better one for my bike but haven't made my mind up on putting the versys radiator or leaving the Ninja. So far the Ninja has word fine.
I am concerned about the airflow, I'll be doing a lot of local rides this summer to test it out before I go out west later this year. This thing has so much power (for me) that I am never working it very hard, so I think it will be ok.
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Old 06-04-2012, 08:15 PM   #360
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Here is the bike with the lengthened swing arm and painted fairing. Just got back from an 800 mile ride to Road America last weekend. Was riding with a couple sport tourers, so it was pavement all the way. The bike works great on pavement, the only issue was with the newly added fairing and windscreen mounts the windscreen buzzes really bad between 3000 - 4000 RPM. This has to get sorted out.





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