Building lightweight racer project! - - The home of the Kawasaki EX500 / Ninja 500R
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post #1 of 4 (permalink) Old 7-14-2019, 5:32 PM Thread Starter
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Location: S.F. Bay Area
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Building lightweight racer project!

Hi, I've been active over on past couple years when I picked up Ninja 250 race bike. Been doing 7-races and +40 trackdays per year since.

With recent domination of Ninja 400 due to its light weight, it's been beating up on everything and would finish mid-pack in Open/1000cc classes. I'm looking at building lightweight racer from EX500 with custom chromoly frame. I got through university building custom bike-frames for cycling-team (TdF style). Did 12-years of road/crit & 6-yrs velodrome racing myself.

Picked up 2 non-running EX500s for cheap. A 2006 with blown motor and 2005 with with missing front-end and wheels. Mixed and matched to get 2005 complete and running.

Now onwards to building frame. Will model after RC390's geometry as I really like handling on that bike. It's doing really well in MotoAmerica's JR-Cup races, just need additional 10-20hp. Which is where EX500 engine comes in...

A lot of this is new for me, but I think I have background for anything. Real specialty is EFI-tuning and turbo systems. Used to have shop upgrading Porsche Turbos. With ECU-remapping alone, I can extract +100bhp from Porsche Turbo.

Last edited by DannoXYZ; 7-14-2019 at 5:42 PM.
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post #2 of 4 (permalink) Old 7-14-2019, 5:39 PM
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2006 Ninja500R Purchased new July 2006; 0 miles. Miles as of January 2019; 102,137. It's a GO bike, not a SHOW bike.
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post #3 of 4 (permalink) Old 7-15-2019, 5:25 AM
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Welcome! You may have seen this one.

Or even this one:

1987 EX500-A1<br />K&N/Dynojet kit<br />Webcam 245 cams<br />Cobra F1 slip-ons<br />3rd airbox snorkel<br />Tapered rollers<br />Prog. Springs<br />Russell braided line<br />Galfer pads<br />Avon Super Venoms
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post #4 of 4 (permalink) Old 7-16-2019, 6:48 PM Thread Starter
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Thanks! I actually met Julian Farnam at a north Bay ride couple years ago!

I really like trellis frame on old Ducatis and new Ninja 400.

I'm looking at making something similar to them, like this:

Has more direct connection between head-tube and swingarm-pivot. And under 20-lbs! I'll probably use butted Columbus tubing like those old Ducatis. Some tubes may even be better as conical shape. Gotta brush up on my old Solidworks software. It does have some limited FEA capability, so that should be helpful in analysing stresses.

Last edited by DannoXYZ; 7-16-2019 at 7:01 PM.
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