Dual Sport Ex update - Ex-500.com - The home of the Kawasaki EX500 / Ninja 500R
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post #1 of 80 (permalink) Old 2-12-2011, 2:01 AM Thread Starter
SJB
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Dual Sport Ex update

Here are some pics of my Dual Sport Ninja. I started this project in September of '09 and rode it some last summer. I took it apart this winter and did some more work and painted it. It has been a fun project and a hoot to ride.
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post #2 of 80 (permalink) Old 2-12-2011, 2:19 AM
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Re: Dual Sport Ex update

That's way cool.

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post #3 of 80 (permalink) Old 2-12-2011, 3:55 AM
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Re: Dual Sport Ex update

Oh, Anchorage! What you have is an Alaskan streetbike. Does the chain tear up the swingarm near the pivot?

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post #4 of 80 (permalink) Old 2-12-2011, 8:50 AM
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Re: Dual Sport Ex update

It looks like it would be a lotta fun to ride...I like the paint job Nice work!!

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post #5 of 80 (permalink) Old 2-12-2011, 12:49 PM Thread Starter
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Re: Dual Sport Ex update

Quote:
Originally Posted by PO18GUY
Oh, Anchorage! What you have is an Alaskan streetbike. Does the chain tear up the swingarm near the pivot?
No problems with the chain. I used the stock KLR chain guide. It has a KLR650 swing arm and a KL600 front end on it. Gives about 10" travel in front and around 8-9" in rear.
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post #6 of 80 (permalink) Old 2-12-2011, 12:59 PM
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Re: Dual Sport Ex update

How awesome is that? Great license plate, too.

Did you switch to bigger wheels? Also. what tires are those?

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post #7 of 80 (permalink) Old 2-12-2011, 2:06 PM
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Re: Dual Sport Ex update

Sweet!!!! I thought about doing something similar to my 03!!

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post #8 of 80 (permalink) Old 2-12-2011, 5:40 PM
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Re: Dual Sport Ex update

Quote:
Originally Posted by SJB
Quote:
Originally Posted by PO18GUY
Oh, Anchorage! What you have is an Alaskan streetbike. Does the chain tear up the swingarm near the pivot?
No problems with the chain. I used the stock KLR chain guide. It has a KLR650 swing arm and a KL600 front end on it. Gives about 10" travel in front and around 8-9" in rear.
Once again, ingenuity picks up where the factory dropped the ball. Great job!

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 #9 of 80 (permalink) Old 2-12-2011, 6:33 PM Thread Starter
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Re: Dual Sport Ex update

Quote:
Originally Posted by Youcanrunnaked
How awesome is that? Great license plate, too.

Did you switch to bigger wheels? Also. what tires are those?

Stock Ninja wheels with Kenda tires. Had to go with tubes though.
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post #10 of 80 (permalink) Old 2-13-2011, 6:52 AM
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Re: Dual Sport Ex update

That looks fantastic! Great job

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post #11 of 80 (permalink) Old 2-13-2011, 9:13 AM
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Re: Dual Sport Ex update

Very cool I like it a lot.

wanna come over to myspace and twitter my yahoo till I google all over your facebook?
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post #12 of 80 (permalink) Old 2-13-2011, 11:04 AM
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Re: Dual Sport Ex update

+1

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post #13 of 80 (permalink) Old 2-13-2011, 7:44 PM
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Re: Dual Sport Ex update

now thats a cool machine me thinks myn will under go the same treatment so was there any major alterations to the chassis,suspension etc
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post #14 of 80 (permalink) Old 2-13-2011, 7:50 PM
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Re: Dual Sport Ex update

Quote:
Originally Posted by barnsleyracergpz500s
now thats a cool machine me thinks myn will under go the same treatment so was there any major alterations to the chassis,suspension etc
Did you read the whole thing he said: No problems with the chain. I used the stock KLR chain guide. It has a KLR650 swing arm and a KL600 front end on it. Gives about 10" travel in front and around 8-9" in rear.

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post #15 of 80 (permalink) Old 2-13-2011, 8:18 PM
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Re: Dual Sport Ex update

ive just looked at a klr swinging arm and it looks almost identical to the ex !!!
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post #16 of 80 (permalink) Old 2-14-2011, 12:02 AM
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Re: Dual Sport Ex update

Wow man! A buddy of mine and i did this exact same thing to a 1987 Honda Ascot. Your job looks so much better than ours did...props man!

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post #17 of 80 (permalink) Old 2-14-2011, 5:56 PM
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Re: Dual Sport Ex update

Love the color too! Very clean bike... I want

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post #18 of 80 (permalink) Old 2-14-2011, 10:34 PM Thread Starter
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Re: Dual Sport Ex update

Thanks for the comments. It was not that tough to build once I figured out what components to use. Biggest problem was the top of the steering head flange (had one made to accept the stock KLR taper bearings and welded it on after cutting the Ninja flange off) and then figuring out what worked for the rear linkage and shock. There are lots of little detail things to do, spacers here and there etc...It might actually be easier to use the KLR wheels since I used the KL and KLR suspension but I did not have any and I liked the look of the Ninjas wheels....kinda SM looking. If anybody is interested in build specifics pm me and I'll share what I know.
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post #19 of 80 (permalink) Old 2-14-2011, 11:30 PM
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Re: Dual Sport Ex update

eBay just crashed......

You better get ready to quote conversions dude, you may be on to something here!
Excellent job the bike looks like it rolled off the showroom.

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post #20 of 80 (permalink) Old 2-15-2011, 3:17 AM
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Re: Dual Sport Ex update

What pipes did you use?

By the way I'm in eagle river if you ever feel like starting a Alaskan ex club. haha
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post #21 of 80 (permalink) Old 2-15-2011, 9:14 PM Thread Starter
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Re: Dual Sport Ex update

Quote:
Originally Posted by arctic kawi
What pipes did you use?

By the way I'm in eagle river if you ever feel like starting a Alaskan ex club. haha
There are probably a lot of EX's up here, I see them all summer.
The pipes are stock but the cans on my bike were in rough shape from a PO, so a buddy was putting custom pipes on his brand new Harley and he gave me his stock cans which were like brand new. Makes the bike a little louder but really sounds nice at revs.
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post #22 of 80 (permalink) Old 2-16-2011, 3:52 AM
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Re: Dual Sport Ex update

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Originally Posted by SJB
Quote:
Originally Posted by arctic kawi
What pipes did you use?

By the way I'm in eagle river if you ever feel like starting a Alaskan ex club. haha
There are probably a lot of EX's up here, I see them all summer.
The pipes are stock but the cans on my bike were in rough shape from a PO, so a buddy was putting custom pipes on his brand new Harley and he gave me his stock cans which were like brand new. Makes the bike a little louder but really sounds nice at revs.
Ya I really like the look of the cans but i just wish they were like 5-6 inches shorter. However with your bike raised how it is they look pretty sick.
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post #23 of 80 (permalink) Old 2-16-2011, 10:38 AM
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Re: Dual Sport Ex update

Really nice work!

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post #24 of 80 (permalink) Old 2-28-2011, 9:30 PM Thread Starter
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Re: Dual Sport Ex update

Decided I needed some under seat storage. I went to Target and spent $3.49 on a plastic container with lid. Fabbed up a "skid plate" for it out of an old license plate. Cut the inner fender and mounted everything in place. I sealed the container to the fender with silicone and the seat keeps the lid on tight.
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post #25 of 80 (permalink) Old 2-28-2011, 10:03 PM
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Re: Dual Sport Ex update

Brilliant sir. Here I have seen and even tried fabricating something from metal sheeting and you go and drop a 4$ plastic tub in from Wal Mart. I sir, am Jealous.

You don't get bonus points from 9k crashless miles, but you get scars from 30 yards of asphalt.<br />
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