Project Full Circle:Ninja 650 gets a makeover

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

  1. Salsa

    Salsa Been here awhile

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    The secret to mounting things with bolts is to have the bolts in tension and sheer and NOT in bending.

    Imagine holding a shelf bracket on the wall with one finger and pushing down at the end of the bracket with the other hand.

    Push down
    here
    _______
    | Push against the wall here (1)
    |
    |
    | OR here (2)

    If you are pushing against the wall at (1), the bolt is in tension and sheer.

    If you are pushing against the wall at (2), the bolt is in bending.

    You need some leverage below the bolt to change the stress from bending to tension.

    Don
  2. 13.1

    13.1 Shaken not Stirred

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    exactly!!!!......well, sorta

    this this exercise has a couple purposes
    here are some that i see as i havebeen reading most of these rat-ninja builds:
    1. to relocate the pegs more forward, and maybe down just a bit, so a more dirt bike stance can be attained
    2. to strengthen up the obviously weak street bike casting by building a custom mount
    3. to allow a slightly different shifter/shifter linkage
    4. to allow use of and the mounting of "real dirt type footpegs"
    5. to also address the brake pedal, and to be able to use a stronger, less breakable pedal
    6. make the system/parts so, if a successful build, it can be easily duplicated for others to follow
    7. pls add what i left out guys

    beemer

    .
    .
  3. sailah

    sailah Lampin' it

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    haven't really looked at it yet to be honest other than glancing at it from time to time.

    I'm probably going to work on modifying the seat pan to get a comfortable seating position and bar reach first and allow that to dictate where the pegs end up. To that end we might find that our mounts aren't compatible for me to send you mine as my seating position is going to be a few inches forward from all of you guys and the pegs might feel weird.

    It might make more sense to just draw some up for you using ktmklx already good design and add on the tabs for pegs or whatever. The actual peg mounts we could leave blank so each user could decide where they wanted them and weld them up to the plate onsite.

    Either way I'm happy to help with either cad drawing or getting these cut out from my water jet guy but I don't want to get too far off in the weeds on a side project, hope you understand that, I'm also in the not enough time dept too:evil
  4. sanjoh

    sanjoh Purveyor of Light

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    That's the right approach IMO.

    I will say you get a lot done with the time you have! I've noticed a lot more thought going in to this build, remember reading/watching the FZ build and thinking about the movie Edward Scissorhands only you would have a cutoff saw, welder and really big sledge on the ends:D
  5. sailah

    sailah Lampin' it

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    ^^^ truth^^^:D
  6. kellymac530

    kellymac530 motorcycle addict

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    Older CR pegs are 8mm and 8mm not 12mm. We are talking about the BOLT diameter not the head/wrench size right? And they are threaded into just aluminum...not a ton of tensil in that. I personally thing that pic of the ktmklx sanjoh posted is more than enough for average NON triple jumping stuff. JMHO though, and I have been called an idiot....no savant attached to it. :lol3

    If you are cantilevering the peg mount very far down and forward, especially down, then yes I would add a gusset maybe at a 45* angle back up under to the frame, or if it is a clear shot, then all the way accross to the other peg even to balance out load.
  7. sailah

    sailah Lampin' it

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    Nothing major although I got my new-to-me KTM 640 low fender. I need to make some custom brackets to be able to bolt it to the RFS forklegs and also to raise it up slightly over stock. I dig the look should be sweet with the rally fairing.

    [​IMG]
  8. dentvet

    dentvet Long timer

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    12mm bolt diameter but its probably moot because sailah likes to join stuff with molten liquid metal. We just need to sit back and see what he comes up with when he gets to that point

    I like the idea of joining the pegs under the cradle though....

    centerstand might be nice, too... just kidding:D
  9. sailah

    sailah Lampin' it

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    Holy crap:lol3 You guys are pushing your luck:rofl

    I'm going to weld mine, bolts be damned, anyone else is free to do whatever the hell they want.
  10. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

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    Question: Maybe i missed any discussion on this - but i see you have a Braking front brake caliper on this. Is this the 32mm 2-piston version? And if so, how do you like how it works? I think the stock KTM Brembo's are 28mm, so i would think this is a better caliper for the bigger bikes with single front discs.

    Im liking this build! Very creative.
  11. sailah

    sailah Lampin' it

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    Jim,

    It's a 320 rotor, caliper and master cylinder from Braking, bought it used from someone in the FM who had it on a 640 Adventure. I had this on my CBR600 build which I only put 200ish miles on so no long term report. I will say it works incredibly well. One finger could easily throw you over the bars, will make a front knob squirm under heavy braking.

    I have the weirdest leak from the master cylinder, it has this one tiny wet spot under the pivot (that sounded really bad:lol3). It never gets to the point where it drips, fluid stays the same. I wonder if it is some residual fluid caught between the two seals? Anyways getting a rebuild kit had to come form Italy and was stupid expensive for a couple seals.

    I had never had a really nice brake setup other than Brembos but these 320mm rotors with the correct master cylinder are impressive.

    BTW, I hate to say I am biased but I remember seeing your thread title and I was like, great a Harley build. Then I recall you discussing a CNC billet swingarm and I was GLUED to the thread. Your execution and attention to detail was incredible to follow. My bikes always end up looking like a high school shop class:lol3 I'm trying hard with this one not to go ghetto...
  12. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

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    That sounds like a great set-up. Thanks for the details. I have the same 320mm Braking rotor, but still the stock KTM Brembo caliper and master cylinder. I think this Braking caliper may be just what the bike needs. The Brembo does OK, but not great. Im getting old now, so i think i want less effort stoping.

    I still have the stock HD rear caliper too, so this Braking may also be a better lighter fix too. We shall see.

    Watch out for that wet spot :evil

    Keep up the good work. Its all good when we end up with a cool custom bike we envisioned.
  13. sailah

    sailah Lampin' it

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    I hate to spend your money, but the braking is phenomenal. I don't think you need to match it with Braking, in fact based on how hard it is to get parts for them I would go with a sumo caliper and master cylinder from Brembo, Motomaster etc. Motostrano has some nice pieces to peruse.
  14. sailah

    sailah Lampin' it

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    Yeah my pegs are going to be much further away from the bolts than KTMKLX.

    I did however look into the CRF peg MOUNTS. I was going to use a KTM peg, but they have the mounts welded to the frame which means I need to make the mount. The Hondas you referenced have that mount that bolts to the frame. Which means I can buy a pair on eBay and weld them to my mount. Then just get a nice set of IMS pegs for a Honda and bolt right on. Thanks for the lead, that made that project a lot easier.
  15. JimmyTheHog

    JimmyTheHog Low Speed Adventurer

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    Thanks, Im a motostrano recovering addict. Now i may fall off the wagon and have to check them out. They do have nice stuff. The danger is that i live only minutes from their shop. Stop me !!!!! :lol3
  16. LukasM

    LukasM Long timer

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    Looking good Pete! If you want to save yourself a couple of hours of fabrication I think the RRP brackets are worth the $80:

    http://www.rally-raidproducts.co.uk/rallye-rally-accesories-/ktm-690-exc-low-fender-brackets

    [​IMG]
  17. sailah

    sailah Lampin' it

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    Lukas I've seen those and the RMS versions. For such a simple piece of aluminum I have to try it myself first. But as usual, you are probably right and I'll spend 5 hours making 4 silly brackets when I could have been doing something else. That's my problem, I'm cheap in the worst possible way, spending money like a drunken sailor on bling and not on the important stuff.:lol3

    Sent you a PM too.
  18. dentvet

    dentvet Long timer

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    Do you want me to send the CRF mounts I have? 2004? crf 250 mounts
  19. sailah

    sailah Lampin' it

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    Dent thanks but you'll need them I think. I'll just get some on ebay and others can do the same. Unless you have more than one set
  20. LukasM

    LukasM Long timer

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    Yeah, I figured it would be about $20 per hour saved and you'd end up with a nicer product. But since you've got a TIG welder and you are definitely handy with the grinder give it a shot. :D

    I've got a set of the Mecasystem brackets at home, those are the ones that RMS sells. I can take some detailed pictures for you this weekend so you can build something similar, you don't want your fender coming loose and those are Dakar tested.