Project Shinjimei- 73 TX500

Dreadrock, I'm still on the fence on that one.... I do like the idea, but I put a bit of work into making my battery tray, and I'd hate to have to cut it off to make room. And I do like the twin shocks.
That said...
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I have looked into it. This fella used the stock swingarm and welded on his own brace/shock mount .
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it also looks like he completely re-did the rear frame section. I don't have a problem with that, but like I said, I have work into the path I've started on.
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He started with a different plan. If I'm going to do all the work of converting to a mono-shock, I want the ass end up a little higher. Nice to have another builder's work to reference, though. If when the swingarm arrives I discover I can fit a shock below my battery tray, I might go that route. No matter what though, this IS the way i'm cutting off the rear frame tubes... Wait and see!
 
I've spent the past few days going over old posts on several forums looking for anything I might have missed, and I came across a few regarding the cracking of the head that I had forgotten about. The theory is that the original gasket material could act as an insulator, keeping heat localized near the hot exhaust valves or, more accurately, not allowing heat to naturally dissipate through several layers of gasket into the surrounding metal. I mention this because my engine is still dis-assembled while I procrastinate on getting the cylinders hot-tanked, and it affords me the opportunity to make improvements.
I'm impatient, but I'm (hopefully) not stupid. I already put the two pieces of the head together with a factory fiber gasket, but my new gasket kit has a nice metal and rubber one - I'm betting it's better. So I'll take that back apart. Now that I have two different styles of head gasket, I'm toying with using them to pattern a hybrid of the two and make one out of copper. I have access to material and a lazer cutter... Even If I don't know how to use it. That's the toying part. •﹏•
Copper head gasket=not likely.
That said, the one in the kit (again) looks to be an update, with exposed aluminum between the cylinders, molded in, as well as several copper inserts at the locations for the cylinder studs, oil passages, and locating dowels - also exposed. I know I spent good money on both pieces of the later style head gasket, but I have better. I choose better.
Maybe now is a good time to look for an RD transmission..... 6 speeds is better than 5.... Even If I can't afford it.... And maybe it's time to cut off dead weight and reconsider some things I've already started, just in case something better is possible. Mono-shock?
 
Oh Yeah - just for clarification;
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this is what my bike looks like right now. Ha ha!
 
Well, I have my Ninja 250 swingarm. I will post pictures, but let's be honesty, it's January in Wisconsin. I don't really feel motivated to work in the cold. Trust me when I say, though, I'm excited about the doors it opens for me. It is a little wider at the back, so I'll need to make up some new spaces for the wheel, but more importantly, it's a little longer. Updates to follow.
 
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Well, I managed to brave the cold (12 frigging degrees ) long enough to remove the stock swingarm for a side-by-side comparison with the EX250 part. As expected, the pivot bolt is the same diameter, so I'll be able to use the TX bit, after I narrow the pivot area of the Ex swinger about 6mm. In this pic, you can see the extra length, as well. I was surprised to find the TX axle is a little bigger than the EX bit, though.
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Of course, the new arm is a little wider at the rear, as well. The TX axle isn't quite long enough to work, so I figure I can use an EX axle, and get new bearings to match the wheel to it, or I can have a new axle made up in the TX diameter, and mill out the axle plates to it. Horse apiece I guess...
 
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Just a pic showing how much wider the Ninja swingarm is at the axle. My buddy the machinist is working on spinning up a longer axle and some new spacers for me so the wheel will center in the same place. I will have the axle holes in the Ninja swingarm bored out to fit the new axle.
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just a quick-and-dirty print of the specs for the new axle.

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Also, here I have the spacer tube from the EX pivot bolt set in front of the TX swingarm to illustrate how much the Ninja swingarm needs to be narrowed at the pivot. I'll have that done at the same time as the axle holes, and have shock mounts welded onto it as well. ( I have decided on twin shocks. If I change my mind, I'll still have the monoshock mounts on the swingarm.)
Tentatively, I've decided to use the drum brake on the rear. I will need to add a bracket for the torque arm, but I'll be leaving the one for the Ninja disc as well- again, in case I change my mind later.
 
Im likeing it sir ! How much longer is the new swinger from the old TX one ? Why not run rear disk on that bad boy ? Or even run the EX rear wheel and EX whole front end ? Not trying to 2nd guess just throwing ideas out there !!!! Keep at it man my shops cold but not that cold might want to stand infront of the frig to warm up ;D
 
Lol! Yeah, it's friggin cold out there! I just think the EX wheels are ugly, I would never use 16 inch wheels, and I've got a plan regarding the front end... The junkyard where I used to get stuff for my S12 Silvia has a crashed Hyosung GT650R.... I figure I can get the whole front end minus wheel for under $200. Inverted!
I am seriously dead-set on spokes, but I would like to try and lace up a pair of wider alloy 18s... As far as using the drum out back, it's a pretty strong brake. In fact, it was considered "too powerful" in its day. Plus, I think it'll look really cool with some holes drilled in it and some brass-and-stainless mesh in the holes.
The EX swingarm is about an inch and a half longer than the TX piece. With my über-long shocks, it should help get the ass end down where I need it, since I can move the lower mounts back that much....
 
This is one of my favorite projects to watch. Keep at it man. I hear you on the cold stuff I'm in that neighboring state to the West. ;)
 
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Crappy pic, I know, but I just had to illustrate the new gussets I made up in anticipation of my rear frame modifications. If you look on the ledge behind the bike, you'll see the piece I'd rectangular tube I cut them off of.
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While I was in the garage, I pulled the factory seals out of the Ninja swingarm to see how much material I had to work with to narrow the pivot. After I narrowed the center sleeve, I found:
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None. I have to shave all the way up to the bearings' outer surfaces. Thankfully, and strangely conveniently, the stock external seals from the TX fit perfectly on the EX swingarm..... Hopefully I don't have to take any material off the frame...
 
Just doing my best to keep the thread alive... I'm waiting on my new rear axle from my machinist buddy. (Made of 316 stainless.) I thought it was kinda weird that it measures 7/8" rather than metric, but I made the measurement myself, so I know that's what it is... Just curious. I'm sure a metric just happens to be identical, so no sense worrying. I'll be taking both swingarms to a local machinist this week (my buddy is in Chippewa Falls) to make the hybridizationhappen. Need to open the Ninja swingarm axle holes up to match the new/old axle, as well as narrow the pivot, and weld on the twin-shock mounts and drum brake torque arm mount, too.
I see bradj's RD from hell, and I want some wheels like his, but I do like the look of the original drum hub.... No matter what, I'm gonna look at getting some aluminum rims and stainless spokes, though. Maybe not right away, but it's going to happen. For the time being, I will most likely just spray-bomb the stock stuff black to hide the rusty spokes....
I have the inverted front end in my sights, just waffling on pulling the trigger. I paid a good price for my aluminum clipons for the 34mm forks, and I picked up fork seals as well, and headlight mounts from DCC, plus the caliper and adaptor.... I want it, and I know it's going to happen...hell, it's even anodized the same color as my shocks! I just have to get over the pain of losing the cool stuff I already bought for the stock front end... Anybody want to buy my stuff? Lol.
Oh, and I bought a welder. Cheap harbor freight 90 amp flux wire. Maybe not good enough for the frame, but I can weld on the new muffler to my header. After I decide which one I want....
 
Well, I did it... I pulled the trigger and bought an inverted front end.... The long, slippery slope continues.... I guess new wheels will be a relatively small step from here. Lol.
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Got the EX swingarm back from the machinist, and decided to make sure it fit. This is just a quick-and-dirty mockup of the lower shock mount location. ( The machinist was... Uncomfortable with doing the welding I wanted, so I'll just have to do it my Damn self.) With the upper mounts still at stock position, there is still a little more droop than I'd like, but that will be taken care of when I move the upper mounts.
Oh, and I have an 18 inch alloy rear rim and stainless spokes to fit a YZ 250 hub on order. Why you might ask? Wait and see!
 
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Got my new front end today, and had to set it in there to see how it looks. Sexy! Amazingly enough, the Yamaha stem is an inch longer, AND larger in diameter- this is going to be a very easy swap.
 
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I decided to test fit my stock front wheel into the new forks to see how much work it would take to use my FZR rotor. Turns out to not be a huge issue. I need to stop at Bearings inc. and get some new bearings to match the wheel to the smaller Hyosung axle, and have my buddy whittle me up some spacers, but mostly looks like more smooth sailing. I'll see how long that lasts when I try fitting my caliper...
Oh, and I have rims and spokes on order. Black anodized 18" aluminum rims and stainless spokes. Turns out MikesXS has spoke sets made up for fitting an 18 to the front, so I bought a set. The 2.15" rim I originally ordered for the rear (with the YZ hub I bought from bradj) will be repurposed to used on the front, because I ordered a WM4.5 (2.75") rim from Buchanan's. Wide as I can go and not have a drop-center, which would require shorter spokes. I worry about the spoke angle, but I only paid 30 bucks for the rim, so if it doesn't work, at least I won't be out much. MikesXS has front 18's, if nothing else.
Damn, I am getting impatient!
 
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Got some godies in the post today! Hub and spokes for the rear (and a caliper setup. Thanks bradj!), rim for the front. Waiting on front spokes and rear rim, then I'm a rotor, chain and sprockets away from having a roller again! Well, as soon as I weld the shock mounts onto the swingarm...
 
Was looking at the front end your using and man I really like it on the bike ! Might have to look into it down the road ::) will be looking forward to seeing the bike on its legs !
 
Thanks, Brad. This should work out killer.
Hey, can't beat 200 bucks for an inverted front end. Who cares if it's Korean? Lol. Have you seen the prices on Japanese stuff? Yeah, I'm looking forward to it, too! Getting closer....
 
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