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Old 09-26-2011, 03:21 PM   #121
pjm204
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Originally Posted by sanjoh View Post
What type of riding are you wanting to do? That usually impacts the direction of the build.

I'll be doing mostly street, 2 track, and some single track. I definitely want front and rear spoked wheels. I'd like 9+ inches of ground clearance, and good suspension front/rear. Obviously the 41mm KLR forks are easier. But I don't mind doing some extra work for far better performance. I'd just rather not do the guess work and complete something that has been somewhat documented.
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Old 09-26-2011, 06:09 PM   #122
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I definitely want front and rear spoked wheels. I'd like 9+ inches of ground clearance, and good suspension front/rear. Obviously the 41mm KLR forks are easier. But I don't mind doing some extra work for far better performance. I'd just rather not do the guess work and complete something that has been somewhat documented.
The rear wheel from a ktm lc4 with a cush drive is an easy swap. Uses the same 20mm axle as the ninja.

What ever you choose for the front end, try and get the whole front end. Other wise you might end up with a bunch of money in it. The biggest challenge is the wide frame of the ninja limits the lock to lock steering available. A wider triple or more offset will provide more steering.
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Old 09-26-2011, 07:02 PM   #123
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So I picked up my donor ninja this weekend. I'm going to start sourcing parts. Still trying to decide what rear wheel to go with, what front end to go with, and what to do with the exhaust. I've been riding the bike as is all weekend an it seems like a great platform for it.

Picked up an 08 with 18 miles on it, minor fairing scratches but otherwise as new. $2000, score. Hoping to sell the fairings, wheels, forks, headlight separately.

Any suggestions for components to use? I looked for 08+ KLR forks but they appear to be pretty pricey, for the price KTM forks seem like a smarter option. Also thinking about dr650, xr650r, or drz400 forks. I just want something I won't have to do a lot of guess work on.
I'm partial to the xr650r or drz400 (pre 2008). Either have full compression and rebound adjustments, are stiff enough to not need a brace, have all the travel you'll need and are very common. You should have no problem finding a complete front end.
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Old 09-27-2011, 06:07 AM   #124
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I'm partial to the xr650r or drz400 (pre 2008). Either have full compression and rebound adjustments, are stiff enough to not need a brace, have all the travel you'll need and are very common. You should have no problem finding a complete front end.
Has anyone used drz400 forks on a ninja build? They're likely my top choice since they are easy to find and likely cheaper than the ktm forks...and maybe since it is sort of a kawasaki model, they will fit easier?
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Old 09-27-2011, 07:13 AM   #125
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Has anyone used drz400 forks on a ninja build? They're likely my top choice since they are easy to find and likely cheaper than the ktm forks...and maybe since it is sort of a kawasaki model, they will fit easier?
See jdrocks gravel burner build. He used em.
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Old 09-27-2011, 07:32 AM   #126
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See jdrocks gravel burner build. He used em.
Thanks, I will have to check it out...I'll be on the lookout for a complete KLX/DRZ400 front end, a KTM LC4 rear wheel, etc
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Old 09-28-2011, 01:24 PM   #127
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Thanks, I will have to check it out...I'll be on the lookout for a complete KLX/DRZ400 front end
PARTS alert, theres a DRZ front end with triples for $125 in the flea market.
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Old 03-27-2012, 06:30 AM   #128
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After a few thousand miles over the last month, it is still my favorite bike!


Stock shock (Sachs) from an Aprilia Dorsoduro will send the seat height skyward. With OAL around 12 3/4" the shock is easiliy adapted to the stock ninja mounts by drilling the the bushings in each end of the shock, the bushings fall out to reveal a nice bearing with a 12mm id. The swingarm bottomed on the stock muffler mount so it was removed.

Best on and off road performance of any shock I've had on the bike. Spring and valving are very close, only issue so far is jumping the bike when loaded
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Old 03-27-2012, 06:48 AM   #129
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After a few thousand miles over the last month, it is still my favorite bike!

Stock shock (Sachs) from an Aprilia Dorsoduro will send the seat height skyward. With OAL around 12 3/4" the shock is easiliy adapted to the stock ninja mounts by drilling the the bushings in each end of the shock, the bushings fall out to reveal a nice bearing with a 12mm id. The swingarm bottomed on the stock muffler mount so it was removed.

Best on and off road performance of any shock I've had on the bike. Spring and valving are very close, only issue so far is jumping the bike when loaded
Hmm...wonder where I can get one of these shocks. I would imagine they don't pop up for sale often.
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Old 03-27-2012, 06:54 AM   #130
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Hmm...wonder where I can get one of these shocks. I would imagine they don't pop up for sale often.
Having a Dorso in the garage, I can say that they are readily available as most Dorso owners think the shock is a POS sounds like a natural fit for a rat builder

If you don't have at least a 32" inseam, don't even consider it.

Check here and your favourite parts source.
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Old 03-27-2012, 06:56 AM   #131
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Having a Dorso in the garage, I can say that they are readily available as most Dorso owners think the shock is a POS sounds like a natural fit for a rat builder

If you don't have at least a 32" inseam, don't even consider it.

Check here and your favourite parts source.
Nice, cheapest one on ebay is $245. I'm actually looking to raise the rear end a bit. The R1 shock helped but a little more would be better. I have a 34" inseam so I should be good to go.
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Old 03-27-2012, 07:07 AM   #132
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I'm actually looking to raise the rear end a bit.
Rat builders love a high tail

Another recent change that has transformed the bike is the gearing. I was running 15/50, went with 15/52 to drop the 1st gear speed as the clutch was getting abused in any tight off road conditions. Works a treat, better acceleration and the bike is much much happier (read smooth) as it gets out of the lumpy area around 3200rpm quickly. Crusie at 75mph 6100rpm yields 51mpg, roll on power will bring a smile to your face. Downside is the speedo is way off, in the range of 5-7mph. A certain German Mfg calls this a feature but has anyone found a cheap way to change the speedo? ps $100 for a speedo healer is not cheap.
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Old 03-27-2012, 07:10 AM   #133
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Rat builders love a high tail

Another recent change that has transformed the bike is the gearing. I was running 15/50, went with 15/52 to drop the 1st gear speed as the clutch was getting abused in any tight off road conditions. Works a treat, better acceleration and the bike is much much happier (read smooth) as it gets out of the lumpy area around 3200rpm quickly. Crusie at 75mph 6100rpm yields 51mpg, roll on power will bring a smile to your face. Downside is the speedo is way off, in the range of 5-7mph. A certain German Mfg calls this a feature but has anyone found a cheap way to change the speedo? ps $100 for a speedo healer is not cheap.
I have a 14t front sprocket coming so I will be running a 14/48, should be close to your gearing. The speedo is already off anyway, what's a few more mph..haha
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Old 03-27-2012, 07:19 AM   #134
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I have a 14t front sprocket coming so I will be running a 14/48, should be close to your gearing. The speedo is already off anyway, what's a few more mph..haha
Should be close.

FYI, the counter sprocket can be impossible to get off, might want to order a replacement nut before you try. I went to get mine off and it isn't going to happen without cutting it off. I tried it with an impact wrench with the bike in gear, big mistake, cam chain jumped a couple of teeth, secured the chain to take load off trans and put 5' breaker bar on it, just bent my 1/2" breaker, one thing lead to another and the lobes have been stripped. Tried with heat, nada, tried every penetrant known to man, nada.

Good luck.

sanjoh screwed with this post 03-27-2012 at 07:37 AM
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Old 03-27-2012, 07:34 AM   #135
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Should be close.

FYI, the counter sprocket can be impossible to get off, might want to order a replacement nut before you try. I went to get mine off and it isn't going to happen without cutting it off. I tried it with an impact wrench with the bike in gear, big mistake, cam chain jumped a couple of teeth, secured the chain to take load off trans and put 5' breaker bar on it, just bent my 1/2" breaker, one thing lead to another and the lobes have been stripped. Tried with heat, nada, tried every penetrant know to man, nada.

Good luck.
Well hopefully mine isn't on there as tight. It is only supposed to be 92ft/lbs. we shall see. I mean at some point the front sprocket needs to come off, they certainly don't last forever.
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