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 Ø60mm (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.