Fitting The ‘ebay’ Exhaust to my TT250

N.B. this post originally appeared in edited form at chinariders.net

I bought my stainless ‘ebay exhaust’ – the one everybody uses – months ago but never had the chance to get it fitted.Screenshot from 2018-05-13 18-48-23 These kits almost fit the TT250, but there’s one definite modification required; you have to widen or cut the flange as it’s not drilled wide enough for the 229cc engine’s exhaust port studs. My neighbour (actually the maintenance guy for place I live in) offered to help me cut the flanges with his grinder and vice. On friday night we did this with the accompanying (somewhat terrifying to the uninitiated) shower of sparks.

I was a bit worried about the studs and cap nuts, already haven taken the bike through winter. In fact they came off with just a light turn of a ring spanner; however the bottom stud unscrewed from the cylinder block rather than the cap nut. The threads were in good condition; but I couldn’t get the cap nut off so resolved to get a spare. Autozone and Advance Auto Parts didn’t have anything suitable – they sold M8 x 1.25 studs but they were too long. A local hardware store had a good selection so I armed myself with a couple of spares. I also bought a nut splitter and some small locking vise grips, placed the grips on the smooth part of the stud and was able to turn it off. My cleaning and scrubbing the nut while it was on the bike had let a lot of WD40 penetrate in and gum up the threads, but it was basically fine, so I put it back on the bike, screwing it in with my fingers. No problems. I bought new nuts and lock washers.

Next challenge was the gasket. I’d ordered a new one from ebay and it’s basically a little copper ring, but I couldn’t see the existing one; I then noticed the exhaust port appeared to have some weirdly machined interior edges. The ‘wet’ spots are some cleaner I had sprayed on earlier:
exhaust port and studs

The photo revealed these were deformed at the top, and I realised I was looking at the existing gasket which had a squared cross section, and had been pretty well squashed. I grabbed it with some needle-nose pliers and it popped out. I put the new one in (I dabbed a little grease on it to make it stick as it kept dropping out and tried the new header for size, screwing the nuts on finger tight to get an idea of fit.

Some people have got lucky with the fit of these things. I knew straight away the clutch arm was going to be close, and I figured it would be a little clearer when it was all tightened up, but for now it made a little ‘tink’ every time I let the clutch lever out.

Secondly on fitting the mid pipe and muffler, it cleared the frame by about 5mm and easily passed under the airbox, but there was absolutely no way I could get it to meet the bolt eye under the seat where everyone usually fixes it. It had about an inch to spare:
exhaust mount gap

I could not move it up as this would bring the pipe into contact with the frame; I could try and bend or dimple it, but it really didn’t have much motion available at all. So I knew I had to make some sort of bracket.

I haven’t made anything out of metal…well, ever, really. I went to Home Depot and found a length of Aluminium ‘flat’ that was three feet long (lol) and two inches wide, and a mini hacksaw. It was .0125 thick, so plenty stiff. I reckoned that If I cut a simple rectangle 12cm x 5cm I could drill holes in it and make a bracket, so that’s what I did. Well, I sort of butchered the holes a bit (I didn’t measure well) but it fitted; you can see it here:
Fabricated bracket

Exhaust clearance to the license plate holder is marginal (I used the included spacer and even bought some nylon ones from Home Depot in case I needed more room) but it’s fine. Lots of riding today, no melting:
Muffler clearance

I was still unhappy about the clutch clearance, so I Googled some advice about how to, er, ‘shape’ exhaust pipes and the most simple way appeard to be to whack it with a ball-peen hammer. So I got a regular ball peen hammer (6 bucks, Harbor Freight) and marked the spot with a sharpie where the clutch actuator was touching, and set about whacking my exhaust. A few blows made the material dimple enough to give about 2mm clearance (it actually increases when bike is hot) and it’s on the underside so not visible.

Last job was to take the carb off and fit the 115 main jet (already had a 27.5 pilot which I knew is a little rich so should be fine with a more open pipe) and put it all back together.

It sounds great, and the bike pulls strongly throughout the rev range. I was pretty pleased with the result.
TT250 with exhaust fitted

Hope this helps somebody.

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As Much As I Hate Winter…

This really put a smile on my face.

There’s always somebody with a delightfully cheery outlook.

The Ninja 400 is here

The king is dead. Long live the King!

It had to happen sooner rather than later. The Ninja 300 has had a five year run, and now Kawasaki has thrown another 100CC at the formula (in what is apparently a new engine, not the re-sleeved ER-6 650cc that has been around for a while.)

102517-2018-kawasaki-ninja-400-hi_18EX400J_540GN2NRS3CG_A_001
Photo credit: Unknown. Found on This Ninja 300 forum

Some numbers:

  • 33.4KW/45ps @ 10,000rpm
  • 38nm/28 ft.lb @ 8000rpm
  • 17.6lbs lighter than the Ninja 300

So it’s got quite a bit more poke, and weighs less, that’s quite something. The H2-derived styling isn’t bad, it’s a very consistent family look now; the 2017 Ninja 650 has these cues too, along with the handlebar and dash style.

That’s as much as anyone really knows. I look forward to the reviews. No doubt the demo truck will be doing the rounds in summer, I’ll try and get a ride in if there’s one close by.

I have to say though, I really wonder where this leaves the 650.

All Engines Great and Small

You Always Want What You Don’t Have

I spend all of my riding time on small bore bikes, by US standards. My Ninja 300 at 296cc and the CSC TT250 weighing in at 229cc.

The Ninja will – realistically – pull to about 75mph easily, above which there’s a tardy roll-on to about a top speed of 105, with my 210lbs astride it, at least. The TT250 will achieve 55-60 with nearly linear acceleration. The gearing limits it, with the engine turning almost 7000 rpm. It is possible to gear down via losing a couple of teeth on the rear sprocket, but I do not want to lose any more pull as it is about perfect for the hilly terrain here.

Both are easily quick enough for the street and back roads, but the TT250 isn’t really suited for superslab, at least not allowing for a safety margin.

If you take a 300 on a group ride and you have a lot of seat time on it, you’ll have no problem keeping up, assuming you’re not blasting down an expressway. On a technical road it’s a giant killer. It’s light, stops fairly well thanks to docile brakes and strong engine-braking, and turns in sharply. At around 18ft.lbs peak torque, you can pull silly amounts of throttle and it won’t get out of shape. In short, it’s easy to ride quickly. Get used to people telling you they’re surprised how fast it runs in a pack. It’s a truism that few riders (here, at least) have experienced the limits of their bikes, so they’re surprised how quick a ‘learner bike’ can run in familiar hands. They’ve just not spent enough time on one.

Ninja 300 territory

The TT250 is an absolute blast on tight, nasty roads with a poor surface, thanks to generous suspension travel. A very driveable engine with modest torque, it delivers power a lot more evenly than the piquey 300, but obviously there’s less of it. The bike’s turn-in is very rapid (it’s light at 320 lbs.) and it feels glued to the road thanks to relatively soft tyres. You can easily imagine why Dual Sports are such popular street bikes, not to mention their street-tyred derivative, the SuperMoto.

The downsides? Going uphill. Street bikes in the >500cc class will climb a hill while maintaining good acceleration. My 300 is okay as long as you keep the revs high. The TT250 really doesn’t like it; again my weight doesn’t help and maintaining some kind of fitness would help matters a lot. Aerodynamic drag, which squares with speed, is another. I’m 6’3″, and make a nice sail while sitting on the bike. Tucking low on the Ninja, stomach on the tank, makes a huge difference and I can’t reach the bike’s top speed without it. Running tight roads uphill is often easier in the TT250 due to the engine’s much wider torque characteristics, and short gearing. On a group ride, riders on torquey bikes will typically eat your lunch when accelerating out of tight uphill corners.

My recreational riding on Western PA’s fantastic roads is at a speed regime that is squarely within the 300’s performance envelope. Interestingly, this also goes for everyone I ride with, and that includes someone with a Superduke 1290. I too want a bigger bike sometime soon, and I’ve spent this year riding a few. So why, if all of my needs are met?

Well, they’re not. More power is more fun, and it’s also another thing to master. It’s why we ride, right? There’s more. With larger bikes come bigger tyres, typically better suspension, and stronger brakes. These usually bring a step in performance too. There is a specific scenario any small-bore rider is familiar with – and that’s overtaking. This is a most fraught area when you’re new to riding, as you don’t have enough power exactly where you need it, that is around 50-60mph with a small time window to get around a car. Overtaking is a reality when you’re on an aggressive ride; it’s a necessity. You have to learn to do it and you must know exactly what your bike will do. When in a group you need to exercise highly-disciplined judgement as everyone else will typically have a lot more power available, and they will use it to pass where you cannot.

There is also the matter of work. There’s a fine line between rider engagement and simply being busy, and on a long country ride at spirited speeds, you can be regularly at full throttle while constantly, constanty rowing through the gears. It adds up over a day. Being able to use a fraction of a bike’s performance to run at a pace your comfortable with makes a difference to your fatigue level. The 1000cc class bikes I’ve ridden have been an interesting change in workload. They are by no means ‘easier’ to ride, but they can be less work due to simply having far more performance available in a given situation.

A friend of mine finally sold her pre-gen Ninja 250 last year, and bought a rather handsome Yamaha FZ6R. She’s an excellent rider, and one of the things she was emphatic about was how relaxed it was on the highway, in terms of comfort and smoothness, so she arrived at the twisties with no stress. These things start to matter to you, after a while.

Summer Blues

August 8th, 2017

I’ve been riding a lot, but I haven’t been writing a lot. It’s definitely not been due to a lack of things to say; but time’s played a part. I’ve been spending a lot of quality time with my kid, and Summer’s been pretty fun outside of problems with my bête noir, the Pittsburgh weather.

I’ve ridden a lot of bikes; more Ducatis, some Yamahas, and a Suzuki, so that’s a target crossed off this year (I wanted to get a lot more demo rides in).

I’ve also made some more riding friends and been out on group rides a few times, and bike nights have been a blast.

I have also, truth be told, experienced a little fatigue towards riding, although everytime I hop on the Ninja I’m invigorated. I think it’s some irritation toward the lack of any real bike culture here, so riding becomes a little close to tedium at times, and tedium is a very efficient passion killer.

I’ll write some more about this, I need to think carefully about how I word it as I may come off as a little harsh.

We will see.

Be Paranoid

If you think they’re out to kill you, it’s because they behave as if they are.
Crane Truck McFuckface was hiding in this tunnel
The tunnel monster is real

Riding to work this morning on my dual sport, I negotiated this blind corner and came upon a stationary utility truck (the type with the dorsally-mounted crane) head-on smack in the middle of the road.

My guess is that the driver did this to allow the crane to clear the tunnel ceiling. Be that as it may, it was poor judgement as the this tunnel has a blind entry on both sides:

Blind entry to tunnel in both directions
Blind entrance, both ends

I’m assuming the driver had his window down, heard me, and stopped. There were no lights, no flag man, nothing. Had I been riding more aggressively than was prudent, had I been on my sport bike, this might have been a little hairy; you can see it is an appealing pair of corners; that’s why I ride this little road in the first place.

Ride safe, folks.