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ok couple of things, first i want a pic of under the seat so i can see the layout of wiring :) secondly what did you set your tire circumference at for the bike speedo.... I set mine at 1760 which is what yours should be of course that is in mm's. Last thing she is looking good bro Keep up the work man.
 

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The man WITHOUT a plan
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Discussion Starter · #22 ·
Yeah I used the 1760 from your post. I think the issue might have been the angle the magnet was passing it. It's temporary anyways, my birthday is in 4 days and I should hopefully be getting a GPS unit.

There is a LOT of room under your seat once you remove that rear fender and put something along the bottom of the upper subframe rail. I just let the electronics fall as they may on it and secured them so there wouldn't be a lot of tension. That whole assembly of crap from the right side of the bike is resting snugly in that space in front of the tank mount, plenty of air to keep it cool, but i need to ziptie it off just to make sure.
 

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Custom bikeporn addict.
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Ok an update.

Pictures :D

New headlight and bicycle speedometer(isn't quite working correctly at the moment...repositioned the sensors to see if that will help)



My new coolant reservoir.


Before wire/electronics tuck.


After wire/electronics tuck.


As she sits now. Stickers are to draw attention away from nasty dents in tank. Cleaned a good 5 years of road grime and buildup off of her. Also...will be replacing the aluminum undertail and battery tray with a fully enclosed fiberglass one. Just wanted to be able to test the space and i couldn't get cardboard to do what I wanted so I went with ali. Definitely like how it's started, and will probably leave it the way it is for now.

Since last picture post...added bar-ends(had to cut almost an inch off the bolts), replaced headlight and speedo, removed airbox and side panels, installed K&N air filter and crankcase breather filter. Plus some things already mentioned.



On the drawing board... replacing those pegs/levers or getting rearset kits and try to find a non-**** windscreen for 7" headlight. Help or input in that area would be greatly appreciated. Also considering putting an rs125 tail on the bike, but may wait until wintertime to do the work that would require.
Looking really good.

Buell blast windscreen maybe?

Bob
 

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The man WITHOUT a plan
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442 Posts
Discussion Starter · #26 ·
Ok I need help.

I need new rearsets. I can get any rearsets that fit any ex250(the 08+ ones fit according to a couple of members here)

I found these for roughly 240 shipped.... http://www.ebay.com/itm/250R-EX250-...=350515018893&ps=63&clkid=6985128512084809186

Should I spend the extra 100+ to get vortex or woodcraft? Does anyone have any recommendations? My shift link, shifter, and break lever are mangled and have to be replaced, but the stock position is very uncomfortable for me anyways.
 

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RUST REMOVER
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I think I have a Buell BLAST! windscreen, they're kinda rare. PM me if you want it.
 

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The man WITHOUT a plan
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442 Posts
Discussion Starter · #28 ·
Awesome. PMed. More pressing issue is the rearsets, though. I had my foot slip off the half-peg on the right while taking a turn faster than I had business going. I am glad all i lost was a bit of boot, but I don't want to keep riding with these.

Another thought was to get the 08+ rearsets and a yoshi extension to bring them back and up so my feet are further from the ground and I can actually ride with my feet over the rear brake instead of under it.
 

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RUST REMOVER
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That tuck looks awesome BTW, nice job.
 

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The man WITHOUT a plan
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Discussion Starter · #30 ·
Thanks. This thing went from being a ride-able get fixed and ride while working on the gpz project to my main focus. I'm obsessed with this little thing. Handles the twisties 100x better for me. Although I think it may just be the fact that it is a more appropriate fit for my skill level.
 

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RUST REMOVER
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I would go with the WoodCraft's they make excellent products. You don't want to mess with no-name rearsets, I would be nervous they could break and that would SUCK!
 

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The man WITHOUT a plan
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Discussion Starter · #32 ·
Thanks for the help. I didn't want to end up getting the acerbis of rearsets. I think I'll order them from moto, said he could have them shipped for about the same price i find them everywhere else. All of the other brands aside from rsv and vortex were priced at or more than what I paid for the bike so they were well out of range.
 

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Custom bikeporn addict.
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Awesome. PMed. More pressing issue is the rearsets, though. I had my foot slip off the half-peg on the right while taking a turn faster than I had business going. I am glad all i lost was a bit of boot, but I don't want to keep riding with these.

Another thought was to get the 08+ rearsets and a yoshi extension to bring them back and up so my feet are further from the ground and I can actually ride with my feet over the rear brake instead of under it.
The 08+ rearsets look nice and if the yoshi relocation adapters work then you'll only end up spending around the $220 that you thinking for the chinese rearsets.

Sounds like the best option to me.

Bob
 

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The man WITHOUT a plan
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442 Posts
Discussion Starter · #35 ·
Got mine off in about 10 mins. I put my heatgun up to the bar end and held it there until the rubber on my grips started to have wisps of smoke come up(but before they actually started melting) and then used a phillips screwdriver to undo them.

Of course, I then proceeded to try to catch the first one when it fell off...don't repeat that mistake. Replaced bar ends with bar-end mirrors and BLUE loctite.
 

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The man WITHOUT a plan
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Discussion Starter · #36 ·
I'll show you guys what I did with my wiring when I re-run them with the fiberglass I'm planning to do. I'm going to try and relocate my battery above the filter and below the tank and the electronics under the tail...but haven't quite gotten that far yet. Everything but the rectifier and rear light wires are actually in that massive cavity at the back of the tank that was left when I removed the airbox. That whole assembly can be placed in there without modification if you cut the zip ties on the sides of the frame and pull on the harness a bit.
 

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The man WITHOUT a plan
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Discussion Starter · #37 ·
Yesterday I tore everything back down to the frame, and picked up a new battery that will fit under the tank.





I then cut some aliminum to make a new under-seat tray thing.




And how she sat before I installed a license plate light.


The license plate is mounted flush on the K&N filter to help protect it a bit.

Also moved the catch can and put the cargo hooks back on and ran a bungee to strap extra stuff down if I need to and as a temporary way to keep the seat pegs in their holes.


And yes...the under-tray is orange. I was testing it to see how it looked. A bit darker than the orange I'm looking for to use in another application.
 

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The man WITHOUT a plan
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Discussion Starter · #39 ·
I synced the carbs with a homemade manometer(sp?) using bar and chain oil in a tube since the ATF was just turning into a slurry and making readings impossible. Long story short, bike runs like cracked out horse at the kentucky derby with a glue truck behind it. Very impressed with the 'feel' of power coming from this little baby bike. Neighbors didn't appreciate the bit of smoke from the carbs sucking in a little ATF, but I don't appreciate their fucking pomeranians barking day and night, so I'll call it even.
 

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The man WITHOUT a plan
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442 Posts
Discussion Starter · #40 ·
Ordered this stuff awhile back, should be showing up after I get back from my field exercise next Monday except the race tail which should show up first week of April...

Honda RS125 race tail. Will be 2 1/2 too narrow at the front. Will be making a glass copy when it comes in to practice fab on. Most beautiful race tail on the market imo. Somewhere between I'll gouge your eyes out with a spoon and cafe tail.

Replacing my broken pegs


Pazzo knock-offs: Picked blue with 'gold' adjusters.





I need to find a way to protect the motor and the rest of the bike. I'm trying to figure out if the new gen swingarm spools will work, now just to find some way to deal with the front. Any advice is appreciated.
 
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