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How to build your own track bike: Difference between revisions

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'''(Looks don't matter; function does)'''
'''(Looks don't matter; function does)'''


*Low mileage w/ good-running engine
*Low mileage w/ good-running engine


*Ugly OK
*Ugly OK


*Busted-up fairings OK
*Busted-up fairings OK


*Dented exhaust OK
*Dented exhaust OK


*Broken bars OK
*Broken bars OK


*Broken turn signals and mirrors OK
*Broken turn signals and mirrors OK


*Thrashed seat OK (should be repairable)
*Thrashed seat OK (should be repairable)


*Dents in tank OK
*Dents in tank OK


*Scratched paint OK
*Scratched paint OK


*Broken headlight OK
*Broken headlight OK


*Crashed is fine, but not crashed "hard"
*Crashed is fine, but not crashed "hard"


*Wheels perfect or nearly so
*Wheels perfect or nearly so


*Frame / Forks not bent
*Frame / Forks not bent


===To Do List===
===To Do List===


*Quality rear stand  
*Quality rear stand  


*[[Stainless steel brake lines upgrade.|SS brake lines]] (buy) (optional *)
*[[Stainless steel brake lines upgrade.|SS brake lines]] (buy) (optional *)


*[[I'd like to know more about clipons.|Woodcraft Lowered Risers]]
*[[I'd like to know more about clipons.|Woodcraft Lowered Risers]]
*Woodcraft Rearsets (optional)


*EBC HH or other quality [[What replacement pads should I consider?|front brake pads]]
*Woodcraft Rearsets (optional)


*Have head ported  (optional *)
*EBC HH or other quality [[What replacement pads should I consider?|front brake pads]]


*Drill oil filter and drain plug bolts & safety wire
*Have head ported  (optional *)


*[[Engine Oil|Oil and filter change]] (quality stuff)
*Drill oil filter and drain plug bolts & safety wire


*[[How do I work on the carbs?|Clean or rebuild carbs]]  
*[[Engine Oil|Oil and filter change]] (quality stuff)


*[[Exhaust|Ugly aftermarket exhaust]] (optional *)
*[[How do I work on the carbs?|Clean or rebuild carbs]]  


*Spend $ on dyno to verify jetting
*[[Exhaust|Ugly aftermarket exhaust]]  (optional *)


*[[Suspension|Quality rear shock]]
*Spend $ on dyno to verify jetting


*[[Suspension|Redo forks]] to race spec 
*[[Suspension|Quality rear shock]]  


*[[What tire makes are available that fit the 250?|Install quality tires]] (Dunlop GT501)
*[[Suspension|Redo forks]] to race spec 


*Verify [[How do I adjust chain/rear wheel alignment?|wheel alignment]] and runout
*[[What tire makes are available that fit the 250?|Install quality tires]] (Dunlop GT501)


*[[How do I measure chain slack?|Proper chain tension]] and worthiness
*Verify [[How do I adjust chain/rear wheel alignment?|wheel alignment]] and runout


*Learn how to work with fiberglass and
*[[How do I measure chain slack?|Proper chain tension]] and worthiness


*[[Body plastics repair guide|repair fairings]] as needed (cosmetics no biggie)
*Learn how to work with fiberglass and


*Buy/make bellypan (optional *)
*[[Body plastics repair guide|repair fairings]] as needed (cosmetics no biggie)


*[[How do I raise the front fender to fit a 110-width tire?|Modify front fender]]
*Buy/make bellypan (optional *)


*[[How do I service the cooling system?|Change out antifreeze]] to "water wetter" and water mix
*[[How do I raise the front fender to fit a 110-width tire?|Modify front fender]]
 
*[[How do I service the cooling system?|Change out antifreeze]] to "water wetter" and water mix


===Remove===
===Remove===


*Headlight assembly
*Headlight assembly


*Turn signals
*Turn signals


*Mirrors
*Mirrors


*Chain guard (optional *)
*Chain guard (optional *)


*Rear fender assembly
*Rear fender assembly


*Smog system if installed
*Smog system if installed


*Rear brake light assembly (optional *)
*Rear brake light assembly (optional *)


*Speedometer cable (optional *)
*Speedometer cable (optional *)


*Side and center stands
*Side and center stands


===Inspect and Repair/Replace/Adjust as needed===
===Inspect and Repair/Replace/Adjust as needed===


*Steering head bearings
*Steering head bearings


*[[Replacing the wheel bearings|Wheel bearings]]
*[[Replacing the wheel bearings|Wheel bearings]]


*[[Final Drive|Chain & sprockets]] (stock gearing is fine)
*[[Final Drive|Chain & sprockets]] (stock gearing is fine)


*Front fender
*Front fender


*Radiator
*Radiator


*Handlebars and grips
*Handlebars and grips


*Control pods
*Control pods


*All cables
*All cables


*[[Waterproofing your electrical connections|All electrical connections]]
*[[Waterproofing your electrical connections|All electrical connections]]


*Axles and hardware (washers, spacers and nuts)
*Axles and hardware (washers, spacers and nuts)


*Rear brake [[Brakes|pads and fluid]]
*Rear brake [[Brakes|pads and fluid]]


*[[Suspension|Fork oil and dust seals]]
*[[Suspension|Fork oil and dust seals]]


*Chain tensioners
*Chain tensioners


*All nuts, screws and bolts
*All nuts, screws and bolts


===Minimal Bike Spares list===
===Minimal Bike Spares list===


*Front brake and clutch levers
*Front brake and clutch levers


*Footpeg and bracket assemblies (optional *)
*Footpeg and bracket assemblies (optional *)


*Spare handlebars (optional *)
*Spare handlebars (optional *)


*Clutch and throttle cables (optional *)
*Clutch and throttle cables (optional *)


*One set spare spark plugs
*One set spare spark plugs


*Oil and filter
*Oil and filter


*Electrical tape and 6 ft. of 12 gauge insulated wire
*Electrical tape and 6 ft. of 12 gauge insulated wire


*Duct tape (of course!)
*Duct tape (of course!)


(optional *) items aren't really required, fractionally enhance bike performance, are too expensive, time consuming, or are not absolutely required for track days.
(optional *) items aren't really required, fractionally enhance bike performance, are too expensive, time consuming, or are not absolutely required for track days.


'''NOTE''': Be aware that plenty of EX250 race bikes are sold each year, usually from October through March. You will likely get a better, cheaper, completely set up bike buying one of these than doing all this on your own. But then, what fun would that be?
'''NOTE''': Be aware that plenty of EX250 race bikes are sold each year, usually from October through March. You will likely get a better, cheaper, completely set up bike buying one of these than doing all this on your own. But then, what fun would that be?
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