Shorty
XS650 Enthusiast
Figured I would post up my info from this weekend. Might be helpful if anyone is looking for a cheaper front end swap option. Ninja 500 parts are dirt cheap, Gives you 37mm forks with modern brakes. I picked up this whole front end with all brakes, master cylinder, wheel, (tire w/ the nubbies still on it) fender (which I will probably sell) and triples, for $100 off craigslist.
Please excuse the bike itself...has a long way to come
Both the XS and the Ninja have steel lower triples with the stem pressed in and welded at the bottom. I found some info online and decided I would attempt this myself. Took about an hour with a grinder, cutoff wheel, and a big hammer
Bottom on my 72 Triple with wear marks and lots of rust
Bottom of the 09 Ninja triple before I took everything apart
And we start grinding
Ground both of them down until I could see weld lines. Got a socket on one and a bolt on the other, couple smacks with a hammer and they came right out.
And the best news of the day. The base of my 72 stem was the EXACT same size as the 09 Ninja 500. Tapped it right in.
My only hold up now is that I need to open up the top hole on the Ninja upper triple so the sleeve/nut on the top will come through. Might not be necessary on the newer ones, But on my 72 thats what I will have to do. Once my bearings come in, I will test fit everything together, Tack the bottom of the stem and pull everything apart. Then I will just weld it all up, Throw some paint on it and onto the next step I will update once I get the top done and show the finished product.
Like I said, not everyones cup of tea, But for a cheap upgrade over my seized, rusted 72 34mm forks, it was win win!
Please excuse the bike itself...has a long way to come
Both the XS and the Ninja have steel lower triples with the stem pressed in and welded at the bottom. I found some info online and decided I would attempt this myself. Took about an hour with a grinder, cutoff wheel, and a big hammer
Bottom on my 72 Triple with wear marks and lots of rust
Bottom of the 09 Ninja triple before I took everything apart
And we start grinding
Ground both of them down until I could see weld lines. Got a socket on one and a bolt on the other, couple smacks with a hammer and they came right out.
And the best news of the day. The base of my 72 stem was the EXACT same size as the 09 Ninja 500. Tapped it right in.
My only hold up now is that I need to open up the top hole on the Ninja upper triple so the sleeve/nut on the top will come through. Might not be necessary on the newer ones, But on my 72 thats what I will have to do. Once my bearings come in, I will test fit everything together, Tack the bottom of the stem and pull everything apart. Then I will just weld it all up, Throw some paint on it and onto the next step
I will update once I get the top done and show the finished product.Like I said, not everyones cup of tea, But for a cheap upgrade over my seized, rusted 72 34mm forks, it was win win!
