"" Frankenbike project - Ex-500.com - The home of the Kawasaki EX500 / Ninja 500R
 
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post #1 of 6 (permalink) Old 1-25-2017, 7:33 AM Thread Starter
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Frankenbike project

Hi guys..

Wanted to post my project with swapping a lot of parts since i bought my bike post-drop from standstill and a lot of stuff needed to be fixed.. .

Maybe some of my experiences can be useful since I often check back to this site before doing some stuff..

Lets see if I can even keep track of all the shenanigans I have been up to...

First, I swapped on an ER-5 rear wheel complete with sprocket carrier etc. It is pretty much plug&play because the ER-5 no matter year also rocks a drum brake like my gen1 EX500... only thing is that the axle bushing needs to be swapped to ER5 as well.. the brake rods moves about half an inch but that's no problem to move

My exhaust was old, rusty and the right can was slightly leaky.. So I got on a pair of ER-5 headers as well .. Not plug and play .. The exhaust bracket doesn't fit, the pipe gets obstructed by the center stand and the right bracket for the underbelly is also in the way .. A bit modding later it is on, and to my surprise a 2003 R6 Termignoni Slip-on can fits neatly on the ER5 headers 60mm (dunno what that is in Murica squareknuckles). I got the Termignoni can very cheap (probably because the guy had lost the hanger .. A Yoshimura Tri-Oval hanger I found laying around was heated and modded to fit) I can recommend a long can for this bike! it eats up a lot of the bad noise you would have with a stubby and gives you some bassy goodness. It's clamped on with a car universal clamp for now ..I'm waiting for my neat T-bolt clamp in the mail..

Since my clutch cover was slightly leaky under pressure as well from the drop, I fitted on an ER5 part here as well. I noticed that the ER5 cover is more reinforced on the inside than the Gen1 cover. I don't know about the Gen2 EX cover. haven't seen the inside of one. (notice grey-metal cover on the last picture). Plastic oil plug is also upgraded to metal.

My front fairing was shot as well, the classic indicator punch-through. I got a hold of a GPz750R front fairing with inner fairing trims and fairing bracket. to my surprise the fairing bracket fits neatly in 2/3 points, namely the sides .. I am after the initial pre-fitting last weekend now modding the front mounting point to fit my frame... For the record. ex500 mirrors and GPz750r/GPz900r mirrors are completely swappable ... Also the GPz750r front rocks a standard rectangular 7x6" headlight.. So I can basically fit anything in there to my great joy..

From here, I am going to take off all fairings and paint them, clean up the bike underneath, make a FOG mod to my filter, (I have a euro version, so my pilot screws are not blocked) change plugs and such. I was thinking if I could fit some FOG dogbones as well that would be sweet. (Does he still sell those or?)

Please ask if you have any questions about the parts I have fitted, since I have found a lot of cross-compatible stuff.

/Loke
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post #2 of 6 (permalink) Old 1-25-2017, 12:35 PM
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Nice swap!

And yeah, FOG still does them.
Have to e-mail him.

O_E_M
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post #3 of 6 (permalink) Old 1-25-2017, 12:54 PM
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That fairing is known in the States as a GPz900 Ninja fairing. I believe the bike was sold in the EU (750/900) for much longer than it was in the states. Maybe not as "aero" as the EX fairing, but you will have a few guessing there. Nice job of subbing parts, overall. And a carbon can in the deal? Sweet!

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 6 (permalink) Old 3-11-2017, 7:10 AM Thread Starter
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Hi Guys!

Update on my project..
-Got my speedo/tach fixed and mounted as per the instructions found in here. I made the bracket from old parts of the fairing stay and rubber bushings I had lying around

Primed and painted the front pearl white, keeping the original blue/silver stripe (@PO18GUY, the fairing for the gpz900 ninja/ gpz750r is identical save the color scheme!)

-Test fitted my full LED headlight (From a Jeep, adds to the Franken-Factor, no?) -Still waiting for my gpz900 headlight rim in the mail ...

Got my KN filter in there and a fogmod, pilots are stock at 2 1/4 turns, we'll see how that turns out..

And first ride of the year! (Keep in mind it's cold AF here in the tiny nordic island kingdom, so we just got above freezing last week) I usually ride fully geared but was just going to get gas 3 mins away with no headlight.. Indicators are delayed as well, but I can ride without legally here since my bike is older than most current pop stars.
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post #5 of 6 (permalink) Old 3-11-2017, 7:40 AM
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Cool! Excellent progress so far!

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 #6 of 6 (permalink) Old 3-20-2017, 12:14 PM
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Quote:
Originally Posted by LokiCopenhagen View Post
Indicators are delayed as well, but I can ride without legally here since my bike is older than most current pop stars.
Haha! That's awesome. Quote of the week right there!! I like what you've done Loke, it looks like it all belongs together. I haven't been by this place much in the last 6 months, and honestly, wouldn't have even bothered with logging in but after reading your thread, I had to. Looks good man, and I look forward to reading more from you.........sean


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