Re: Making of Kawasaki Ninja 300 San

This is one of the best and cleanest thread i have ever come across. Very nicely explained. Kudos to abhimanyu31.

I wonder, can some of those mods be done on a CBR 250R. I am intersted in below things :

1. Engine Ice Coolant.
2. Steel braided break lines
3. Scottoiler E System chain oiler.

Please let me know the prices of the above.

Cheers,
Sanjay




Sent from my LT28h using xBhp Connect mobile app

Motozone Titanium 6AL-4V Suspension Rod Ties

Motozone Titanium 6AL-4V Suspension Rod Ties

Reducing weight on Ninja SanMotozone Titanium 6AL-4V Suspension Rod Ties
Stock Rod Tie: 263 gms

Our choice of material to reduce weight while still keeping the component as strong as the stock one is Titanium. Discovered by Reverend William Gregor, an English pastor in 1791, titanium is as strong as stainless steel and twice as strong as aluminum while weighing 45% lighter than steel and only 60% heavier than aluminum. This makes it an ideal material to use for our custom-made rod ties.

Once again Vikram of Motozone was given the task for developing the suspension rod ties from titanium 6AL-4V. Taking advantage of the strength provided by titanium, the dimensions of the tie rods were optimised and made as light as possible.

The finished titanium rod ties weigh 98 gms each giving us an over all saving of 392 gms. This has been another successful undertaking.


Titanium Rod Tie: 97.4 gms


Stock vs. Motozone Rods




Motozone Titanium Rod Ties

Now, where to find that 200 gms to reduce? The journey continues.

Re: Motozone Titanium 6AL-4V Suspension Rod Ties

Hi Abhimanyu,
just a bit curious , any engine mods in the pipeline ? and just guessing, custom parts within the engine like the cams and valves materials when changed can give substantial change in performance right ? I am not so sure how it will make the bike behave , what is your view on this ?

Cheers
Ride Safe
Krishna

Re: Motozone Titanium 6AL-4V Suspension Rod Ties

Hi Krishna,

Yes there are a host of engine mods in the pipeline. From cutting friction in the engine to reducing reciprocating mass to increasing combustion efficiency, a lot is being planned. While increasing power, we also want to maintain the street friendly character of the bike as it will be used on the street and not the track.

Re: Motozone Titanium 6AL-4V Suspension Rod Ties

Read the entire thread from beginning. Not sure how I missed it. Hats off to your passion n dedication !

Need some info on "Ballistic Lithium Iron Battery". Could you please share the cost of battery (landing cost) and source from where you ordered ?

Re: Motozone Titanium 6AL-4V Suspension Rod Ties

As i have mentioned in the post related to Ballistic Lithium Iron Battery, fellow Xbhpian Archit Kumar helped me source the battery. Archit worked out the deal with sportsbiketrackgear.com for the battery and the charger along with some of the stuff that he was ordering for himself. In total I paid around Rs. 12,000/- for everything.

You can order the battery from Ballistic - Sport Bike Track Gear or from https://www.ballisticparts.com.

Re: Motozone Titanium 6AL-4V Suspension Rod Ties

Thank you Abhimanyu. Let me check out.

I read couple on reviews (link) saying "Ballistic Lithium Iron Battery" gives up in cold starts and is not water proof. Have you faced anything issues as such for Indian climate ?

Re: Motozone Titanium 6AL-4V Suspension Rod Ties

Absolutely no problems. Starts on the first crank and runs like stock. The cold start problems are associated with near zero degrees temperatures.

Re: Motozone Titanium 6AL-4V Suspension Rod Ties

Hi abhimanyu,
since the day you started this thread, there has been nothing but exceptional depth of modification; bringing out the true meaning of the word. I have been hooked on ever since, to say the least.


I just needed one clarity about your description of: MicroBlue Hybrid Ceramic Ball Bearings
Scroll to the line where you've mentioned
If those figures were correctly put, one might notice the fact that steel balls have lesser variation that the hybrid ceramic ones. Mathematically, 50 millionths of an inch is less than 10 millionth of an inch. No?
Did you accidentally exchange steel and ceramic figures there? Because if that is not the case, then technically it is too big a number (for material tolerances/design/strength) to overlook. A little more clarity here would be helpful.
Cheers!

Re: Motozone Titanium 6AL-4V Suspension Rod Ties

Nope, its the other way round. 'Mil' (millionths) is basically U.S. unit of what we refer to as 'Thou' i.e. "thousandth of inch". The conversion is as follows:

1 thou (mil) = 0.025 millimeters. Therefore;

50 thou (mil) x 0.025 = 1.27 millimeters. Whereas;

10 thou (mil) x 0.025 = 0.25 millimeters.

Thus the steel balls have an acceptable production variation of +/- 1.27 millimeters.

And the ceramic balls have an acceptable production variation of +/- 0.25 millimeters.

Now if you are wondering why there is so much of difference, the answer is in the way steel balls are made. Steel balls start out their lives as a wire that is sheared (cut) to the size of the outer diameter of the require ball size. The sheared pallet then goes through a process called 'heading' wherein it is cold pressed into a 'ball'. After 'heading' process the ball goes through 'de-flashing' where the welding line formed from 2 halves of the 'heading' die are removed. This de-flashing process has a certain accuracy rate and while it is able to do a reasonable job it cannot remove the weld line completely.

Therefore, most steel ball bearings will live within the above mentioned tolerances. That is not to say that there cannot be steel ball bearings which have better accuracy balls. There can and will be. However, due to cherry picked steel balls (to achieve tighter accuracy), such steel ball bearings will be quite expensive and are used only in places where specialised applications demand such bearings.

In the case of ceramic balls, they start their lives as Silicon Nitride power which are made into a ball shape through a process called Sintering. Due the Sintering process there are no weld marks on the balls. Therefore, after being ground to the required shape and size they tend to have better accuracy and less deviation.

In addition to the above production variation, the steel balls require greater amount of clearance when fitted in to the steel races. This is due to the fact that steel balls will require space to expand as they heat up during operation. Ceramic balls have lesser thermal expansion vis-a-vis steel balls. Therefore, ceramic ball bearings can be built to much tighter tolerances and create lesser friction than steel balls bearings.

Re: Motozone Titanium 6AL-4V Suspension Rod Ties

Thanks for the clarification there. Just because of the '-th' suffix, I wrongly thought that numbers are expressed as 1/50 million (for 50 millionth) :O

Lightech 7075 T6 Aluminum Bolt Kits (Engine/ Frame/ Fairing/ Fuel Tank Cap)

Lightech 7075 T6 Aluminum Bolt Kits (Engine/ Frame/ Fairing/ Fuel Tank Cap)

We ended our pervious post with a question; “Now, where to find that 200 gms to reduce? The journey continues”.

Our journey has taken us to a very unlikely place i.e. fasteners. So what are fasteners? A fastener is a device that mechanically joins or affixes two or more objects together.

In a way the story of modern civilization is the story of fasteners. Without advancement of fastening technology, civilization could not have progressed. Imagine a world without fasteners. Is there any product in your day-to-day life that does not have fastener in some form or the other?

The most common type of fastener is the blot. Bolts are one of the most common elements used in modern construction and machine design. Consider this; the Ninja 300 has over 170 different fastening torque specifications. Each of these torque values have been decided upon based on the size of the bolt, its yield strength and the application at hand. For example, the crankcase bolts of size M8 have a recommended torque specification of 23.5 Nm whereas cylinder head bolts of size M8 have a recommended torque specification of 32 Nm.

Therefore, while bolts may not be sexy and glamorous, they literally hold your bike together.

So what does all of this have to do with weight reduction? There are literally hundreds of parts on your bike, which require hundreds of fasteners to join and affix to each other. Even if each fastener is a few grams in weight, the total weight of all the fasteners will be quite substantial. Let us suppose that there are 100 fasteners in the chassis frame. Now imagine that if you could reduce 2 gms per each fastener. In the end you would be saving 200 gms in weight. Lord Buddha’s words of wisdom ‘A jug fills drop by drop’ are everlastingly fulfilled.

7075 T6 Aluminum Blot Kits

While considering the replacement of bolts for weight reduction we considered 2 companies i.e. ProBolt and Lightech. As a company Lightech is famous for its Rizoma brand of accessories. My experience with these accessories has been excellent and therefore I preferred ordering Lightech’s aluminum bolt kits.

The following kits were ordered from Vikram of Motozone who are dealers for Lightech:

1. Ninja 300 Fairing Kit – 45 bolts.
2. Ninja 300 Engine Bolt Kit – 25 bolts.
3. Ninja 300 Frame Bolt Kit – 27 bolts.
4. Ninja 250 Fuel Tank Cap Kit – 6 bolts.

As we wanted to maintain the red and white theme, the bolts were ordered in red colour.


Lightech 7075 T6 Bolt Kits


Weight of Fuel Tank Cap Bolts - 21.8 gms.


Weight of Lightech Fuel Tank Cap Bolts - 7.6 gms.




Lightech Fuel Tank Bolts - Each bolt is carefully torqued to the right specification.


Stock Rear Foot Rest Bolts - 48.6 gms.


Lightech Rear Foot Rest Bolts - 17.8 gms.


Lighttech Rear Foot Rest Bolts.


Weight of 4 Stock Engine Cover Bolts - 30.4 gms


Weight of 4 Lightech Engine Cover Bolts - 10.7 gms


Lightech Engine Cover Bolts






Total Number of Bolts replaced - 352.9 gms

We save a total of 260 gms with this particular change.









Acknowledgements: Special thanks to Motozone and my friend Farhan Shaikh for making this change possible.

Re: Lightech 7075 T6 Aluminum Bolt Kits (Engine/ Frame/ Fairing/ Fuel Tank Cap)

this is one thread that i have read like 3 times end to end.. crazy amount of commitment and love for your bike.. just wondering.. you might have as well bought a busa for that kinda money invested in the 300..

Re: Lightech 7075 T6 Aluminum Bolt Kits (Engine/ Frame/ Fairing/ Fuel Tank Cap)

Forget about the gains we are getting here. This thread just simply an eye opener for many of us about the possibilities of performance mods. Kudos!

Re: Lightech 7075 T6 Aluminum Bolt Kits (Engine/ Frame/ Fairing/ Fuel Tank Cap)

The attention to detail u have put is mesmerisizg