LINKS TO OUR NEW TOOLS AND EQUIPMENT: https://linktr.ee/BuildBreakRepeatChannel (Amazon Affiliate Links, if you buy something using our links it will help the channel!)
CHECK OUT OUR INSTAGRAM! https://instagram.com/build.break.repeat?igshid=ulwwhmio96an
Now that we are moved into the new garage, we’ve been taking our time to revive old projects. First up on the plate was the Manco Deuce with custom suspension and a Ninja 250 shifter engine. We’ve always struggled to get the shifter mechanism correct because of the force exerted by the shift lever and the articulation of the back suspension. We came up with a design that uses a hard linkage using heim joints from the lever to the rear suspension. Then that hard linkage connected to a B&M 3’ shifter cable (link below) that can flex to allow for the suspension travel. It ended up working great and we took it for a rip to test it out!
Thanks for watching, stay safe and stay tuned for the next video!

MERCH

MERCHANDISE CUSTOM DESIGNED BY YOURS TRULY
https://teespring.com/stores/build-break-repeat
TOOLS
Texas Metalworks 40x80 Welding Table
https://texasmetalworks.com/product/fully-fabricated-welding-table/
RogueFab Tubing Notcher
https://www.roguefab.com/product/versanotcher-universal-tubing-notcher/
Pro-tools Tubing Bender
https://pro-tools.com/collections/tube-and-pipe-benders
Optrel Crystal 2.0 Welding Mask
https://usa.optrel.com/en/eye_protection_helmets/products/show/crystal20/
Optrel Grinding Mask
https://usa.optrel.com/en/products/augenschutz/helme-zum-schleifen-schneiden/products/show/clearmaxx/
MUSIC
Music - Background and Montage Music Is From Endemic Sounds
https://www.epidemicsound.com/
Intro Song - Jimmi by Andrew Applepie
https://www.youtube.com/watch?v=l1zHz8pYfyQ&ab_channel=AndrewApplepie
—————PARTS—————
DG Ninja 250r Muffler - http://dgperformance.com/dg-performance-models2.php?category=Kawasaki&model=Ninja%20250%20R&appYear=2008&prodType=Exhaust
AUXBEAM LIGHTS -7 inch LED Work Light Bar CREE Flood Beam: http://bit.ly/2JXFhv0 -52 inch 5D-SERIES CREE LED Light Bar Combo Projector Lens: http://bit.ly/2K9HLVX -Save 12% off coupon code: 12LB
Shifter Cable - https://amzn.to/353kxvX (Amazon Affiliate Link)
22 x 11-8 Knobby Tire- https://www.gopowersports.com/22-x-11-8-knobby-tire/?utm_source=YOUTUBE&utm_campaign=Build_Break_Repeat&utm_medium=Video
Go-Kart Steering Kit Complete- https://www.gopowersports.com/go-kart-steering-kit-complete/?gclid=EAIaIQobChMI7ZSjzt7y5QIVjIzICh22TgAlEAQYASABEgJJr_D_BwE/?utm_source=YOUTUBE&utm_campaign=Build_Break_Repeat&utm_medium=Video
20 x 7-8 Knobby Tire- https://www.gopowersports.com/20-x-7-8-knobby-tire/?utm_source=YOUTUBE&utm_campaign=Build_Break_Repeat&utm_medium=Video
Wheels- https://www.gopowersports.com/8-wheel-4-x-4-pattern/?utm_source=YOUTUBE&utm_campaign=Build_Break_Repeat&utm_medium=Video
Axle Bearings- https://www.gopowersports.com/3-hole-axle-bearing-kit/?utm_source=YOUTUBE&utm_campaign=Build_Break_Repeat&utm_medium=Video
Sprocket Hub- https://www.gopowersports.com/1-sprocket-hub/?utm_source=YOUTUBE&utm_campaign=Build_Break_Repeat&utm_medium=Video
Engine Plate- https://www.gopowersports.com/predator-engine-mount-2-420cc-670cc/?utm_source=YOUTUBE&utm_campaign=Build_Break_Repeat&utm_medium=Video
Brake Rotor- https://www.gopowersports.com/blazer-200r-rear-brake-rotor/?utm_source=YOUTUBE&utm_campaign=Build_Break_Repeat&utm_medium=Video
Seats - https://www.gopowersports.com/150cc-driver-seat/?utm_source=YOUTUBE&utm_campaign=Build_Break_Repeat&utm_medium=Video
Seat Belts - https://www.gopowersports.com/5-point-seat-belt/?utm_source=YOUTUBE&utm_campaign=Build_Break_Repeat&utm_medium=Video
Fender - https://www.gopowersports.com/250-300-rear-fender/?utm_source=YOUTUBE&utm_campaign=Build_Break_Repeat&utm_medium=Video
Fender bracket - https://www.gopowersports.com/250-300-left-rear-fender-bracket/?utm_source=YOUTUBE&utm_campaign=Build_Break_Repeat&utm_medium=Video
Fuel Tank - https://www.gopowersports.com/copy-of-large-fuel-tank-2-25-gallons/?utm_source=YOUTUBE&utm_campaign=Build_Break_Repeat&utm_medium=Video
Battery - https://www.gopowersports.com/gtx9-bx-ytx9-bs-go-kart-battery-mainstream-sealed/?utm_source=YOUTUBE&utm_campaign=Build_Break_Repeat&utm_medium=Video
Spring Assisted Shocks - https://www.summitracing.com/parts/gab-43049

We're in the new garage now - and that gives us a perfect opportunity to work on some builds we've neglected. The story of the deuce is when we finished it about a year ago. It was still about 95 done, there's still a lot of loose ends that need to get tied up, although the wiring on it is super clean. The paint on it's super clean all these things.

It's like really close. You know it just needs those odds and ends tightened up with. That being said, that's all we're gon na do we're just gon na get this thing fired up. We're gon na.

Take it for a couple laps, even try to remember what's wrong with it. What we need to fix - because it's been that long since we've worked on it and then hopefully, by the end, we'll be ripping all right. So this thing has been sitting in storage for so long. The battery is just completely dead and it won't hold the charge.

So we have to jump it, but that's: okay. We got the c10 here and dude. Could the battery start well? This is something i haven't seen before. Um.

Let me hook up the jumper cables. It wants to start so um, i'm thinking, maybe the starter. Solenoid is like stuck open or something like that. Maybe it needs to be like cleaned out or something um really, not sure about that.

We haven't had this happen before, but we'll let you know what that is conveniently we have all of our wiring parts in this box right here, so i just have to find that solenoid there we go so yeah right here, so we'll have to check the fuse And then just make sure that's firing when we put 12 volts to it and we'll see if we have a problem. So i just kind of checked the solenoid and like hit it around a little bit because maybe it's just kind of like mechanically stuck and it's all plugged back in. So we have the jumper cables running under the garage since it's cold outside to the truck. And let's see if it does the same sturdy thing, let's see all right! Here's the starter button! Perfect! Okay! So i literally just hit that thing on the side of the box and now it works.

So that's pretty cool uh yeah she's dead, the battery's still dead. Okay, so pretty good, we definitely need a new battery. Obviously the brakes are basically non-existent. You kind of just need to let it bring itself to a stop and then the engine seems to not be running right, so yeah.

I think the first thing we're going to fix is the brakes and the battery, and then after that we'll see if the carbs are synced and stuff like that uh, since we had to buy like three ninjas just to fix this one engine, we have a lot Of brakes, so this is one we had and it's you know like we're just looking at it, it's really crusty and it like barely moves, but we do have the new pads and we can put them on this one which definitely looks worse but should work better. It's kind of sitting there literally no pressure, and it's already clamped, so i think yeah perfect before it was super spiky yeah. We have this old uh super beefy, brake cable from go power sports, and this is from the paddy wagon actually, but now we should be able to just like jam on the brakes because that one used to loosen a bunch. So this would be a lot better.
All right, so our brakes are done. That should be a lot better, nice cool. So we have the brake on and you know, let's see how it goes. Yep, i'm trying yeah i mean once we have a foot pulling on that thing.

It's def. It should be able to lock them up, probably and now after this thing's in we should be ready. Okay, so so it's actually killer what fuel line. Oh my gosh! Okay, that's not good! No, it's shoot the filter just broke.

Well, i'm glad i stopped here. Yeah seems like it just started: dude um. Actually, i think the engine is actually okay like um, it's running really good. The shifter is a little kind of iffy.

I just popped out of gear one time, so i think literally the only thing we got ta. Like look at is the shifter and then this thing might be 100 done. One sec. I need joe to get here so come on brother.

So can you hold this above the gas tank? Okay, all right! Let's try it's our best! This time, oh shoot shoot shoot. Come on good thing, gas is cheap nowadays dude. This is actually a tutorial guys how not to yeah in a gas line. Oh man, hey, hey, hey, hey! We got it really.

Yes, sir. Yes, sir, this ain't never coming off all right, i'm taking a break. My hands hurt all right. Well, it was looking really good.

It was looking like we were about ready to actually take this thing for a bigger rip um. But, of course you know we got the fuel line, fixed jason, adjusted the clutch and stuff and then, as soon as we put it, we're trying to snap it into neutral shifter breaks um. This is the second one. We've gone through the first one.

We went through um was a weaker one, so then we got a stronger automatic, shifter cable and this one broke too spread my hand too. All right so we've been working on this thing for a long time and we actually have made a lot of progress, and this is looking super solid. So we want to make sure that the cable is going in straight and then we also kind of modified the cable, because there's kind of a if you can see this first part of it's solid. So all the sliding is going to be done on the solid part and it's kind of got this whole like box with this tie rod end, so it's all just going to be dead straight in and out no twisting, which was our main problem all right.

So we finally have some good news on this: deuce shifter everything's lined up and tightened down, and it actually works really well so right now it's in neutral and then that is uh second and then back into neutral it. The only thing it doesn't do is return. Super well, but it does like get out of the shift point. So there's no problems there and then um yeah i'll just kind of walk you through it.

So we remounted our clutch. So it's really nice and not held on by electrical tape. And then we have just a like heim joint tie rod end going back to the like hard rod going through. Another tie rod end so that keeps this bar extremely straight, which then pushes the cable in and out dead straight and doesn't bend at all.
So that gets rid of our main weak point. Then it just comes back here. We have a lot of excess and then it just goes to the back. We lengthen the lever arm for the shifter, so it's less stress on the shifter and yeah.

It's pretty simple, but it should be really strong. Well, she died, but yeah. It's just really. Well now, uh really nothing to worry about, basically exactly what we wanted from the first time, so yeah this thing might actually be complete.

So we put a lot of work into the deuce, this video and it all turned out super well and is really solid. So we definitely need to check this thing out a little bit more so stay tuned for next video, because we'll actually be thrashing this thing. Taking it off the road really seeing what it's made of. Thank you powersports.

A lot of these parts on this build are friendly power sports and we couldn't do without them, and thank you all for watching and make sure you stay tuned for next time.

Avatar photo

By YTB

25 thoughts on “Ninja 250 shifter buggy revival! manco deuce returns!”
  1. Avataaar/Circle Created with python_avatars Doc.Cali says:

    Two throttle return springs will help the shifter return. One in front and one in back. Should help.

  2. Avataaar/Circle Created with python_avatars NUNYA BIDNEZ says:

    You guys have come a long way. So proud of you boys. Still showing us the young bucks are gonna make it in the coming years.

  3. Avataaar/Circle Created with python_avatars NUNYA BIDNEZ says:

    Never jump a small engine like this with your car. It may work but the amperage is way too high. I COULD fry the electronics for the engine. Use a jump box set to low or charged lawn and garden tractor battery. Look into it if you don't believe me. Add a return spring to your shifter or get an air shift setup if you wanna be amazing.

  4. Avataaar/Circle Created with python_avatars Jared Pursey says:

    Honestly watched u guys for a solid while. Watching u guys grow up and develop skills is mad. Take a second to think back to the first ever project amazing changes.

  5. Avataaar/Circle Created with python_avatars BiscuitPuncher says:

    Man that geared way low. There are a few other 250 swapped buggies and karts floating around YouTube and they a lot more get up and go for sure.

  6. Avataaar/Circle Created with python_avatars Smitty says:

    I was hoping for a new Deuce video; I'm glad to see it's running better

  7. Avataaar/Circle Created with python_avatars D-Ran Yatertots says:

    Can't jump a motorcycle battery off a car battery, or so I've been told. Very different power levels

  8. Avataaar/Circle Created with python_avatars Uzrnaim1 says:

    Hey guys, when jumping a motorcycle engine from a car, it's best to not have the car running. The higher voltage of the car system while running can damage the bike's electrical systems. Just fyi! An expensive lesson I learned.

  9. Avataaar/Circle Created with python_avatars Nicholas Alvarez says:

    It looked slow and sluggish before y’all worked out the kinks now it looks like it rips

  10. Avataaar/Circle Created with python_avatars Ratatacoon says:

    i wanna build a small car with a full interior and gullwing doors with a ninja 650 in it. its gonna be street legal

  11. Avataaar/Circle Created with python_avatars Chris Grieger says:

    This was my favorite build, by far. Glad to see it back and hope to see more builds like it!

  12. Avataaar/Circle Created with python_avatars JSL says:

    Just not running 100% , sounds like the carbs need balanced. Adjust the clutch and change rear axle sprocket .

  13. Avataaar/Circle Created with python_avatars David Simpson says:

    single cable will not work right you need 2 cable to work. one so when you push your shifter forewed it pulls shifter up on engine and the other cable so when you poll back it pulls the shifter down on the engine why they have it pull back for gear up i dont know that makes no sense to me

  14. Avataaar/Circle Created with python_avatars David Simpson says:

    my motorcycle has the same problem with the starter relay i normaly have to smack the side panel for the relay to loose connection and stop the starter

  15. Avataaar/Circle Created with python_avatars FunTimeGamez ! says:

    Jesus dude why immediately rape it right off a cold start?? Pure stupidity dudes…… that is exactly how you wear your piston rings early and scorch your cylinder walls….. common sense you guys….

  16. Avataaar/Circle Created with python_avatars Randy Hertzberg says:

    why do you make us watch you weld ? After about 3 micro seconds , it's just wasted content. we know you are welding something , so just get on with it.

  17. Avataaar/Circle Created with python_avatars Hoggdoc 1946 says:

    How in the world are these kids affording all this new stuff with only 144K subs, must have family money.

  18. Avataaar/Circle Created with python_avatars Tyler Mayfield says:

    The starter solenoid can weld itself together due to low voltage or high amp draw from continuous prolonged starting. Hitting it on something knocked it lose but it'll happen again if the battery isn't kept charged up. Great work on the rest of it

  19. Avataaar/Circle Created with python_avatars Dave & son's adventures says:

    Looks and sounds to need geared up some. I think it needs a smaller sprocket on the axle.. and or some clutch adjustments

  20. Avataaar/Circle Created with python_avatars DJ Tuning says:

    Looks awesome! You gotta bring that thing out. after all this rain its pretty muddy so you should be able to get that thing caked!

  21. Avataaar/Circle Created with python_avatars Tampa Boys Customs says:

    Man I love this build guys really great job that 250 engine gets it going pretty quick to

  22. Avataaar/Circle Created with python_avatars Tampa Boys Customs says:

    Man I love this build guys really great job that 250 engine gets it going pretty quick to

  23. Avataaar/Circle Created with python_avatars nashguy207 says:

    Great to see the deuce again. Nice work on the clutch cable that should hold up well. Happy New Year to everyone at Build Break Repeat!

  24. Avataaar/Circle Created with python_avatars Prolific Invention says:

    Excellent video as always, do miss the original intro though. Longtime subscriber

  25. Avataaar/Circle Created with python_avatars BryDuhBikeGuy says:

    Awesome guys! New Year starting with a great vid drop that has over 700 views in first hour.Let's see 200K by spring!

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