1984 Ninja 900 - Resurrection of the Assassin!

Discussion in 'Old's Cool' started by RideDualSport.com, May 21, 2011.

  1. RideDualSport.com

    RideDualSport.com TPB all the way

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    <iframe src="http://www.youtube.com/embed/JjKe2tnCwiE" allowfullscreen="" width="425" frameborder="0" height="349"></iframe>

    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.

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    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.

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    The bike shortly after it was built.

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    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.

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

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

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

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    After!
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    #1
  2. RideDualSport.com

    RideDualSport.com TPB all the way

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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.
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    I also polished and sprayed clear coat on the disk carriers. I may be clear-coating the wheels as well.
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    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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    #2
  3. RideDualSport.com

    RideDualSport.com TPB all the way

    Joined:
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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. :beer

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    #3
  4. RideDualSport.com

    RideDualSport.com TPB all the way

    Joined:
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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!

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    Fox Twin-Clicker in all its totally rad rock and roll colors!
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    I polished the wheels and clear coated them with Eastwoods wheel paint.
    New Pirelli Sport Demons round out the package.
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    No cush-drive, the sprocket bolts directly to the hub. This bike is gonna kick butt.
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    #4
  5. lddave

    lddave been there

    Joined:
    Jul 11, 2003
    Oddometer:
    482
    Location:
    Frydek, Texas
    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.
    #5
  6. RideDualSport.com

    RideDualSport.com TPB all the way

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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!
    #6
  7. crawler07

    crawler07 Adventurer

    Joined:
    Oct 19, 2010
    Oddometer:
    60
    Looks great and it feels all so good whan all those small bits come together as a complete unit!!
    #7
  8. RideDualSport.com

    RideDualSport.com TPB all the way

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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.
    #8
  9. RedRocket

    RedRocket Yeah! I want Cheesy Poofs

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    Feb 28, 2003
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    20,595
    Location:
    SoCal
    in. i've always wanted one of those.
    #9
  10. bgoodsoil

    bgoodsoil Dare to be Stupid

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    It's called Obsessive Compulsive Disorder...and we appreciate it :thumb
    #10
  11. RideDualSport.com

    RideDualSport.com TPB all the way

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    Here are a couple of very nice stock and original bikes.... I love it when a bike has never been touched or modified, especially high performance bikes or Adventure bikes that were a milestone in motorcycling history. Younger riders these days, who are not aware of what they are destroying, and have an overwhelming compulsion to express their personality, find cool old bikes on the cheap, then send many bikes to a "cafe racer grave". The cafe racer trend is becoming as permanent and ugly as a bad tattoo. However it is ok to improve on a stock motorcycle so long as nothing has been hacked on by a butcher, so it can be returned to original if desired.
    All the little factory details are intact on these:

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    #11
  12. RideDualSport.com

    RideDualSport.com TPB all the way

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    The rear suspension and wheel are coming together nicely.

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    We also got a better fairing off of e-bay, no cracks or road rash! These are hard to find without the turn signal mounts broken out because the signals are the first to hit the ground if the bike gets laid over. We will need to get some paint color matched to the bike.

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    #12
  13. RideDualSport.com

    RideDualSport.com TPB all the way

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    Well, the Ninja is starting to look like a motorcycle!
    I mounted the fairing, mirrors and signals, tidied up and plugged in the wiring harness.
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    I repainted most of the motor and painted a side cover.
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    The fluid in the clutch master cylinder was cloudy and had some grey crud floating in it, so I re-built it.
    The front and rear brakes will get the same treatment.
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    #13
  14. brucifer

    brucifer Long timer

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    The bike looks great! Nice attention to detail.
    I like your Super TT as well. :thumb
    #14
  15. Sniper X

    Sniper X De Oppresso Liber

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    Incredible rebuild and it is great you are doing this!
    #15
  16. RideDualSport.com

    RideDualSport.com TPB all the way

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    Thanks Sniper and brucifer! I am glad your enjoing the work! I can't believe this bike is 26 years old! Time is really flying by fast. My memories of the 1980's are still so fresh in my mind that it does not seem so long ago that we were racing Ninjas at our local track.
    We found some nice body work on eBAY from a 1986 model, we purchased everthing except the front fairing.
    Here is an example of a cherry 1986, the bodywork we just purchased is not as nice as this bike, but despite some minor cracks an flaws, the original paint is quite nice and we are happy. We will have to paint our front fairing to match the new bodywork.

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    Cheers!
    #16
  17. RideDualSport.com

    RideDualSport.com TPB all the way

    Joined:
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    I sanded the scratches out of the clutch cover, painted it with high temp engine paint and applied the new emblem.:evil
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    Got the ignition cover painted and the new emblem on it too.:evil
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    Installed the chain and chain guard, and torqued the axle bolts... the rear is ready to go!:evil
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    #17
  18. RideDualSport.com

    RideDualSport.com TPB all the way

    Joined:
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    More bling! We bought all the bodywork, except the fairing from a low-mileage bike that was being parted out on ebay. We are going to paint our fairing with the same stock colors as the tank.

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    #18
  19. fyr

    fyr iRoast Coffee

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    Great thread
    I had one of these for 6 yrs back in the early 90's. It brings back some great memories
    #19
  20. fyr

    fyr iRoast Coffee

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    +1 on that!
    #20