Re: Making of Kawasaki Ninja 300 San

I am going to Kawasaki plant this weekend. Cant wait...

Re: Long term Review of Scottoiler system, Rolon X Ring chain & Renthal rear Sprocket

Ah! So you noticed. No, you did not miss out on any update. I thought it was too small an update to put up. As this thread has progressed I think members have been expecting bigger and bigger changes. Whenever I meet a fellow Xbhpian, most times the questions are what is the next big thing? So thought it might not be worthwhile putting the little things that we have been doing almost every other weekend.

Anyway, the story about the red triple clamp is something like this. When we made the first custom made triple clamp and anodized it in red colour in keeping with the White/Red theme that we had selected for Ninja San. The clamp was perfectly anodized and looked great on the bike.

When designed a new clamp for the USD forks, right from the outset we had problems with that clamp. As it was huge slab of aluminum, even after the final machining we had some visible finish flaws. The better the part was finished the more apparent the flaws became. Therefore, it was decided that the part should be sandblasted to remove these flaws and revive any stresses that maybe have been present in billet of aluminum when it was formed.

The sandblasting did remove the flaws and gave the clamp a perfect smooth matt finish. However, it led to another complication. When we sent it for anodizing, the red colour seemed to resist adhesion to the part. The part had to be reprocessed couple of times before it came out satisfactorily in finish and colour shade.

As you noted we had installed the part on the bike and it was looking great. However, due to some reason, the quality of anodizing was not good enough, maybe the pigment used was of not good quality or the process was not followed properly. But for whatever reason, the colour started fading in the bright sunshine and had become a dull whitish red.

Hence, we decided to do the part in hard-anodized process to take care of the colour fade problem. This led to another complication. The hard-anodizing process was available only in two colours; dark grey and black. We selected dark grey as the colour. Also as Motozone has worked so hard on this bike it only deserved that their name and logo go onto the part. Therefore, the Motozone logo and name were laser itched on to the part before it was hard anodized. The results as you can see from the below pictures is more than satisfactory. While not loud like red, the dark grey does give the bike a look of subtle elegance.






We have also added couple of new farkles to the bike. The first one being Lightech handbar ends to complete the handbar looks and the second being the Lightech oil cap. I will let the pictures do the talking now.

LED Head Lights

LED Head Lights

Take a good look at the picture below; that is the concept Honda RC213V-S that Honda unveiled at the EICMA International Motorcycle Exhibition. To know more about this fascinating machine you can take a look at this very interesting Press Kit available over here: 2016 Honda RC213V-S Press Kit - Honda News


Concept Honda RC213V-S with LED Headlights
The LEDs in their box.





The stock H7 Blub setup.


The LED unit & the adapter ring.



Voltage Stabilizer. Note the 30W rating. Stock bulbs are of 55W. The LEDs will provide more luminance while consuming less power.


Adapter ring fitted to the headlight unit. Small modification needed; the retainer spring needs to cut to allow the LED unit to sit properly.


The LED Unit fitted.


The LED switched on.

Initial Impressions Notecost is not a bar

Re: LED Head Lights

Great mod there! Few questions though, Are these LEDs available in other shapes also? Like if I wanted to fit LEDs in Yamaha R3, would I get linear shaped LEDs?

Is the cost very much on the higher side?

Will such a setup void the warranty with the manufacturer?

Re: LED Head Lights

What's the make/model and cost of those led bulbs?

Re: LED Head Lights

Answers in bold;

Please get touch with Vikram of Motozone. If you need his contact details please PM me.

Re: LED Head Lights

I guess the new 2016 Honda CBR500R, got LED lights

Please post few pictures with the light thrown on the wall and in the dark (like you did for the earlier mod)


PS - I was about to request you to write a review on the automatic chain lubrication after my office hours, And when i came back home, co-incidentally the review was already there that day!!
Hope u keep giving us the review of that system time to time. This is the first time I have ever hear of such thing, and have been very impressed by it

Re: LED Head Lights

Yes, surprising isn't it that the CBR500R got LED lights whereas the technological masterpiece got a miss.

I was planning to post pics of the light thrown on the wall once I reached home, unfortunately, just 1/2 km from my home, the bike's rear tyre suffered a uncontrolled deflation when the tyre burst. It was probably due to some sharp stone, the tyre just went "BANG!!!" and the bike lifted atleast a inch in the air from the rear before setting down and into a wobble.

As you will see from the picture the tyre is destroyed. Have source a new tyre, will install it this weekend and then take pictures.

Re: LED Head Lights

Damn.. looks the tyre still Had quite some life left to it!!. i guess these are Metzeller tyres, right!!

Good to Know both u the the Ninja Sans are OK, even with a sudden lift, and wobble!!
All the best with the new tyres

Re: Making of Kawasaki Ninja 300 San

This could not have happened when it burst, looks like you were riding with damaged tyre for sometime and it eventually gave way.

Re: Making of Kawasaki Ninja 300 San

Nope, the tyre was checked just an hour before it happen. What I have not posted yet is the fact that the rear axle and spacers made from titanium have been installed an hour before the incident. The tyre was examined carefully as we were contemplating replacing the tyre as while it seemed to be in good condition, it has lost its profile shape thereby affecting handling in corners. So tyre change was just over the horizon anyway.


Titanium Rear Wheel Axle & Spacers

Re: Making of Kawasaki Ninja 300 San

Sensei hats off to the time and dedication you have spent on your ninja san oh and i assume the bills were quite heavylol
but it surely is one piece!!
#inspired
eagerly waiting for more posts to come from you

Re: Making of Kawasaki Ninja 300 San

So finally found time to replace the rear tyre. I have once again chosen to use Metzeler M5 as I find them to be value for money.

As requested I am posting the pictures of LED headlight beams.


Low Beam.


High Beam.

Note: Before anyone comments; the bike is on the side stand, therefore the beams look slanted.

While I have not been updating this thread as regularly as I would like to, there is much work happening in the background. Further work is much more complicated and intricate and therefore requires lot of planning, hence it will take me sometime to come back with the detail write ups of the next updates. But the wait with be well worth it. Just to give you a glimpse into what we are doing below are pictures of Stage 1 cams that we have procured. These cams are not reground cams. These are virgin build cams that have been made from scratch. Nothing but the best will go on to Ninja San. Enjoy the pics and wait till the next updates !!!!

Re: Making of Kawasaki Ninja 300 San

This is as always amazing stuff

Re: Rizoma Garffio LED Indicator lights

Can you please tell me what material was used for making these mounting plates and how it has lasted over the last year and half or so?