Project Full Circle:Ninja 650 gets a makeover

Discussion in 'Some Assembly Required' started by sailah, Nov 9, 2012.

  1. sailah

    sailah Lampin' it

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    So I just tested it. Filled it full of water and drained it out the fill hose, which is about 12" too long but I don't want to cut it yet. Took 1:24 to fully drain the tank. Well within my tolerances for standing around the gas pump. It's flowing pretty good I will say that. Plus the pressure head put on the gas going into the subtank from the gas in the main tank as I am filling will probably increase the flow rate.
  2. sailah

    sailah Lampin' it

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    Nothing major just finished the tank bung for the fuel fill to the subtank. It's probably 1.75" diameter where I will weld it to the main fuel tank. Fun making these parts on the lathe, I get better every time.

    [​IMG]

    The vent is going to be similar except it will have a bung on the inside of the tank as well so that the vent tube can be attached and run up the inside of the tank. And it will be 1/8 27 NPT instead of the 1/4 18 for the one above.
  3. sailah

    sailah Lampin' it

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    Is it wrong I've been eyeing Aprilia Tuonos and motors seem incredibly cheap?:evil

    [​IMG]

    Manufacturer Aprilia
    Production 2006-2011
    Predecessor Aprilia RSV Tuono
    Successor Aprilia Tuono V4 R
    Class naked bike
    Engine BRP-Rotax V990, 997,62 cc 60° V-twin, 4-stroke, liquid cooled
    Power 99.8 kW (135.7 PS; 133.8 hp) @ 9500 rpm
    Torque 11.9 kg·m (117 N·m; 86 lb·ft) @ 8500 rpm
    Transmission 6-speed, chain drive
    Suspension Front: 43mm fully adjustable Showa Upside-down (USD) forks, rear: Sachs monoshock with adjustable preload and inbound damping
    Brakes front: Dual 320mm disc with radially mounted Brembo calipers, rear: single disc
    Tires Tubeless radial, front: 120/70 ZR 17, rear: 190/50 ZR 17
    Wheelbase 1,415 mm (55.7 in)
    Seat height 830 mm (32.7 in)
    Weight 181 kg (399 lb) (dry)
    Fuel capacity 18 litres (1,098.4 cu in)


    OK back on track here...:wink:
  4. Roadracer_Al

    Roadracer_Al louder, louder, louder!

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    I love me some Aprilia.

    I had also noticed that about parting out Aprilias-- I think it has something to do with low production numbers... not a large resale market, so prices are low.
  5. sailah

    sailah Lampin' it

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    Al I think the motors tend to be really reliable and they aren't your typical rice burner buyin so if people wreck they buy new

    Anyways I think it would be a sweet candidate
  6. RedRaptor22

    RedRaptor22 Been here awhile

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    I would make sure it's not one of the ones that maybe never got brought back for the recall they had, I believe in 07 or 08 there was a massive recall for explody motors, the con-rods were snapping due to the wrong metals being used by the supplier i believe.
  7. bk brkr baker

    bk brkr baker Long timer

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    Ninja 650 progect...............hmmm Aprilla 1000 sweet V-twin ..........mission creep ?

    You're right ,though. They're out there for under a dollar per cc.
  8. sanjoh

    sanjoh Purveyor of Light

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    Having had a Futura, you would not be able to run knobbies on it:D Torque monster.

    Seriously thinking about a new Honda 500 as lightweight option

    [​IMG]

    Prolink:clap
    [​IMG]

    [​IMG]
  9. Roadracer_Al

    Roadracer_Al louder, louder, louder!

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    I think I've identified a problem with your project completion process.

    You are easily distracted by


    LOOK! SQUIRREL!


    :rofl:rofl:rofl
  10. sailah

    sailah Lampin' it

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    You have no idea:deal

    Digging that Aprilia frame and the fact they are so cheap. I'd love me another 950 class bike.:clap

    On a side note...I am going to be an instructor (very part time) at Tech Shop here in Pittsburgh. I'm really pumped about it as my normal job is not the most creative (finance related) so I will be doing some classes in the evenings. One of the benefits is a free membership and they have some super cool tools, check out the website for more info. An ADV member is in charge of setting them up and we met up last week for a tour with some local riding buddies. My main creative strength is probably woodworking so I will mainly be teaching that but one of the courses I hope to create is a bike building class. One of my local riding buddies is also a very talented machinist and retired science teacher. He stuffed a ATK 406 engine into a Cannondale frame and he's going to hopefully teach the class with me if we get it approved. I think it would be great to have a couple bikes being made into whatever, hopefully no choppers unless they are really cool.

    I'd really like to have a fun project to demo and was thinking of either that Harley boardtrack racer that Rebuilder is designing or maybe the Aprilia.

    http://www.techshop.ws/
  11. Roadracer_Al

    Roadracer_Al louder, louder, louder!

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    That is so cool that you got that gig. The Tech Shop in San Francisco has a bike night every Thursday. I have an obligation that night every week, so I've never been, but think I'd enjoy it. I did a waterjet class there - what a bitchin machine! Too bad it's so expensive to run, but is sure will do stuff that other technologies won't do.

    In other news... I finally got the power in my house upgraded to a 240v/200a service -- we had been running on just 110v/45a. Limited me to MIG welding. I ran a few TIG beads the other day, and wow, I had *really* missed that! Its' been a little over 4 years!

    I took delivery of a rotary phase converter on Monday, and finally found the time to wire up my new-to-me Victor 16x40 lathe! Whooo M-Fin' Whooo! I scored some cut-offs from my local scrap yard to make riser feet for the Victor so I don't have to stoop when I operate it. Turns out they are stainless?! The Big Vic just peels 3/8" wide ribbons off. It's crazy... I made a pile of swarf in 10 minutes what would have taken me all day on my crappy little 7x12 Harbor Freight lathe. I'm in love. :raabia:raabia:lol3

    Now I just need to get my mill repaired & reassembled, and I'll be in hog heaven.
  12. sailah

    sailah Lampin' it

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    Thats awesome al congrats on the power upgrade. So nice to use real tools. I'm dying for a mill just no space. I need to move before that will happen.

    I'm excited about tech shop, pretty cool vibe about what they are doing. I can't wait to get my hands on that water jet:D
  13. dentvet

    dentvet Long timer

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    How does that rotax compare to the lc8? I've seen exactly one salvage grade 950 adv bike.
  14. Roadracer_Al

    Roadracer_Al louder, louder, louder!

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    We basically bought our house because it had a full-footprint unfinished ground floor! I didn't think such a thing existed in CA unless you live in the boonies.
  15. sailah

    sailah Lampin' it

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    I've never ridden one but I think that Rotax motor is pretty high spec. Lots more HP than a LC8, more torque too.

    There's a 950 on Copart right now in CA I think.

    I just like weird and not many of those Aprilias around. They seem to go for cheap money too, at least based on what the engines are selling for. I think I would try and find a wrecked one vs buying piecemeal, that always ends up costing a fortune. Not too many around here though and especially when I don't want to screw around with a dealer license to bid dealio.

    Really only one way to find out...:D
  16. sailah

    sailah Lampin' it

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    Been awhile but I got some solid time in at Tech Shop on the bike. Makes a huge difference when you have plenty of space and some really nice tools to use. Got to use the plasma cutter and mig as well as a shrinker and bead roller.

    I cut the tank on the band saw then sanded it on the big disc sander.

    [​IMG]

    I also beat out the huge dent on the left side once I had opened it up. Will def need some bodywork

    [​IMG]

    Tacked the new panel in place. I'm glad I extended the seatpan forward even if just a little. Makes the sitting position very comfortable, and you can stand easily with arms extended to the bars.

    [​IMG]

    [​IMG]

    I need to also bend and weld in a piece for the bottom, then weld in my fitting bung

    If I keep getting in productive days like this the bike should be done in fairly short order. Lots of little finishing projects that can take up an enormous amount of time.
  17. jar944

    jar944 Been here awhile

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    From this angle it looks great
  18. 4play

    4play Next?

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    I have rear suspension envy :deal
  19. LJC

    LJC n00b

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  20. sailah

    sailah Lampin' it

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    I considered it but there are too many potential run ins with fitment around the rear shock. Especially for that money. Plus I like that I can run the original bodywork. Trying very hard to not make this bike look like a rat and using factory parts is key as I am terrible at sheetmetal and fiberglass:evil

    Yeah well maybe if I told you how much I spent and how many hours I have worked on it maybe it would lose some luster:lol3 I can honestly say it was probably not worth all this extra time. I should have explored using a link type rear end, I suspect that would have fit MUCH better and could have possibly eliminated the entire seatpan and tank mods which have been stunting progress here for months it seems. But I'm committed now so I need to follow through.

    I have been playing with AutoCAD Inventor and I'm sure solidworks has a similar feature where you can model the suspension and linkage and see how it moves. I would find a linkage I liked with a swingarm that was a good strong candidate and carefully measure the link points in CAD. Then transfer the whole schebang over to a Ninja and use CAD to get it right. With the shock mounted vertically, and lower, I bet it would fit right in. Plus the Ninja has those two beefy frame spars that would be perfect to weld the shock tower to. Try it by using a YZ450 and report back...:wink: