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[n3rv]

Let’s see where to start, Basically I'm doing a tear down of the bike and general maintenance of the motor as well. The bike is of course a Ninja 500r 2001 with just at 31000 miles on it. The previous own did little to no maintenance to it, when I bought it last summer and I have since put just at 10K miles on it, and have done the basics to it. Well last week the bike got dropped while I was gone for the day. Apparently it rained a ton while I was gone, and the ground go weak and it fell over on its left side. It cracked the upper plastics near the mirror mount badly, and snapped the mirror in half. It also put a lot of scratches on the bike, on top of where the bike had been dropped by the previous owner.
List of things that I will be doing to the bike.

Red = Done

Painting plastics tank and frame
Fixing rear brake line leak that happened over winterization (maybe upgrade lines and rotors)
Adjusting Valve clearances
Cleaning and rebuilding Carbs / sync
New fork seals and possibly springs with (maybe 15w oil) Edit: only 15w oil and seals, for now.
Adjust rear spring and new dog bones (1 inch raise)
LED mod the gage cluster
Under tail mod (not sure of this yet)
Fix cush (has about 1/4 inch of play)
(I'll add more as I think of them)

Anyway I'm still not decide on a color yet, the bike was purple and silver. (Update bike is going to be black frame, and Metalic Brighter Green)
I was possibly thinking Orange frame, and Black plastics. But I'm concerned about keeping the frame/swing arm clean

The bike got new sprockets/chain, smoke windscreen, and Saurachu pipes in October.

Also while I have this thing apart suggest anything that would be good to look at while it’s like this or color schemes would be cool.

I'll be updating this theat will the most important Pictures, but I have many extras of random stuff such as wire layouts and such.
Full Picture Directory is here: http://s257.photobucket.com/albums/hh207/n3rvzilla/Ninja%20500%20Rebuild/

Onto Pictures for the thread!

Early tear down stage


Wow this thing is dirty


Who stole my carbs


I need to pick up a 12MM alen socket in the morning for the front wheel, then take the forks off.


Fixed the cush with the ghetto fablious bike tub mod, no more 1/4inch play in the rear tire  You should have seen how dirty the wheel was from wax!


I think this thing needs a bath, maybe some paint later on


Whoa, parts galore!


I love my Saruchu pipes, they are amazing!



I'll try to update this a much as I can, I'm looking to finish this thing over the next two weeks or so since I have ALOT of free time right now. Suggestions on color, and comments are welcome!

[90ex500]

How long till your selling a box of left over parts?

No really, have fun.  I just finished mine, well I will finish it when I hang the fresh plastic tonight

[Royson]

I'd love to do the same thing next winter to mine.  Strip it all, repaint everything, get a professional repaint of the plastics and swap every tube and bit of rubber out of the bike.  Likely unncessary, but I'd feel great about it!

Oh, and swap in 600cc motor

[90ex500]

I'd love to do the same thing next winter to mine.  Strip it all, repaint everything, get a professional repaint of the plastics and swap every tube and bit of rubber out of the bike.  Likely unncessary, but I'd feel great about it!

Oh, and swap in 600cc motor

Gee, do u think the winters are long enough up there to get all of that done?

[Royson]

Gee, do u think the winters are long enough up there to get all of that done?

LOL, I could tear down and rebuild the bike twice in a Canadian winter. Of course, if I did, I'd have to tear down twice cause I'm screw it up the first time around.

[Tommy69]

while it's torn apart you may as well check out all the bearings and think about replacement or just good cleanings and repacking if in good shape ,and don't forget the swing arm bearings.

[n3rv]

Quick update, I'm still searching for a 12MM Allen to take the darn front wheel off, I think I'm going to just build one with a 12mm bolt and some nuts tomorrow if the last place around here does not have one. Last night I finished cleaning up the rear wheel repacked the bearings (they were pretty dry). I also resurfaced the rear rotor, since it was grooved and repainted the inner area since it was starting to flake badly. Cleaned and started prepping the swing arm for paint.

Some time this afternoon, I plan on finishing the swingarm paint prep. Hopefully get this front wheel off, and the forks from the frame, so I can start paint prep on thoes as well. I'm still debaiting on dog bones from FOG, but I'm thinking I'm not going to be able to afford that just yet. Also I'm not quiet sure how to get the part clamps that hold the forks together off the frame, so any tips would be helpfull. I'm sure I'll figure it out but, insight would be a time saver!

Also I noticed when I was looking at the motor, the sprocket seems loose, but the bolts are thght as can be. I did replace the sprocket a while back, but I might have put it on backwards. I noticed the side facing out ward, has a lip on the front of it, that looks like it might take up the play. Could someone post a picture of their front sprocket mounted, and also see if the "lip" is suppose to be facing inward. I'd say its about 1/8 of an inch or so raised.

Finished wheel, well minus the rotor


High Temp Black Gloss  and surfaced, well under that tape anyway!

[ShadesOfGray]

Lookin' good.

Most places I looked had 10 or 12mm allen wrenches. AutoZone has a lot of the bigger sizes as well, although it's mostly sockets for a 1/2" or 3/8" drive, rather than an actual L-shaped allen wrench.

As for which way the brake rotor is supposed to face, I don't know offhand, but I kind of suspect that it's for that kind of reason that the manual doesn't really recommend disconnecting the rotor from the wheel. 

[GothiUllr]

Sears will have the Allen wrench

[FOG]

All this painting is nice , but,  you might just want to take a tensey weensey peek inside the engine..


FOG

[n3rv]

All this painting is nice , but,  you might just want to take a tensey weensey peek inside the engine..


FOG

Well I don't have a manual, so I don't feel confortable diging into the motor to much. I do plan on adjusting the valves and cleaning the carbs real good. I did stick a optic down into the cylnders and took a look in there, they are pretty much spotless and the sidewalls look good. I was thinking about buying some clutch springs so I might have to crack the side open . Also you should send me some dog bones for free  I'll love you long time! lol

Also for the daily update, no work done today. It sorta stormed out side, see the pics below!

The roof is on fire!


Anybody want an icy?

[Dubcity]

  ooh i have that same bike and year just that i have about 9000 miles on mine , love to hear what turns out .

[n3rv]

What’s up guys, though I’d post a quick post of what has transpired over the last few days. It’s been pretty nasty outside, either to cold or to humid/raining to do much. I’ve pretty much finished up all of the small stuff, and even media blasted the swing arm. I’ve also started my wet sanding prep on the swing arm as well, but it’s still sitting in primer.

Almost finished


Other side same time


Primered and looking good


Thoes rotors look like new!


Tank mount painted, and foot peg holders in primer.


Other gass tank holder, dog bones, and caps for the end of the swingarm (their in primer still)


Silly rad guard


Next set of pics will hopefully involve a fully painted frame. Cheers guys

[n3rv]

Just a quick update, finished preping the frame for primer and its now 100% primered.

Almost ready to paint


Ah, lookie here, I do say it looks nice in grey


Assortment of parts, the triple clamp had to be worked with a bit. The previous owner had the bike stolen at one point and the idiot that stole it gouged the shit out of the poor thing near the ignition. You can see my handy work, I didn't make it perfect just smoothed down the horrible gouges.


Another random parts shot. Looking good I do say so



And just for shits and grins, my friend got his Scorpion Exghaust in today, which got put onto his bike.




So I'd say I'm about 50% done with my work so far, I'll finish up the swing arm and frame tomorrow and start reassembly.

[jay7n]

either your ex500 morph'd during your photo shoot or you slipped in a 650R photo.  EX swingarms never looked that good!

[n3rv]

either your ex500 morph'd during your photo shoot or you slipped in a 650R photo.  EX swingarms never looked that good!

Yeah he brought his 650r out for some mig welding, and to put on that slipon. It sounds pretty damn good. And yeah his swingarm is sexy.

[pi2tb]

The swing arm on the 650 isnt bad looking, no.. i've heard its a direct swap for the kawi versys, which is damn sexy itself.
Nice job on your painting, and good to see someone wearing proper gear when in hail.

[n3rv]

All right pretty big update since I haven't posted in a few days.

Finished adjusting my valves, they were all on the tight side, I'm going to guess they had never been adjusted. The cam lobes all looked to be in great shape, and the chain did as well.
Cleaned the carbs, they were full of gunk and shit, I have no idea how this bike ran, but it would explain why it didn't like to cold start below 50f and sometimes had some flat spots. I did notice that one of the caps in the bottom was removed, while the other was not. Both of the screws were basically all the way in as well, they had like .5 turn till they bottomed out.
Put the swing arm back onto the bike, along with the suspension.
I've put the forks back on, after I put new seals in them, added 15w oil. I'll look into getting an emulator when I have cash for it. I also rocked the forks, but they were pretty much dead on from when I just put them into the triple clams.
The head bearing was almost dry, after I painted the clamps, I made sure to bearing grease them very well and torque the head bearing bolt correctly. It glides so smooth now.

Also on a side note, most of the suspension on the swing arm was very dry, even the roller bearings in the swing arm bolt were dry.


Frame and swingarm, they are so smooth and clean.


I used bbq grill flat black, but the paint seems to sort of rub off (powder on fingers). I might end up repainting these with a 500f semiblack that I used to paint the sides of the motor. I'm not sure how well that paint will protect the pipes since water gets splashed on them some times when their hot.


Took this after I finished adjusting my vales today, just a quick snap shot. I also checked my cam lobes for wear, and the chain. Also made sure the head bolts were proper torque. I also painted the side cases to the motor, both sides had rash on them from the previous owner. I smoothed out the rash, and painted with semi-gloss black. They look like brand new, almost like I powder coated them. I'm going to go back later and paint the "Kawasaki" lettering with whatever color I decide on the plastics.


Quick shot from the back, rear tire is on just to help move it around, I know the brake isn't on it.


Front shot


Kinda weird camera angle down the forks, yes their straight You can see where I did my handle work where it was messed up badly befor. Right around the igntion switch area.

[ShadesOfGray]

Lookin' sweet man.

On a related note, can we start taking wagers as to how many parts will be left over when he's done? 

[n3rv]

Ahhh did I mention I hate routing this fing wire harness around stuff, I'm trying to check to see which pole is neg and postive on the starter since it doesn't say. I'm doing a quick search for it atm, since I can't remember. I'll post pictures of it shortly today, I'm getting very close to having it able to start up

Also this one was from 2 nights ago

[pi2tb]

Lookin great man

[ra88mon88]

Nice bike. What kind of paint are you using. Do you need special paint for the fairings, special primer? Was thinkin about painting mine as well....

[n3rv]

All right guys great news!
I finished wiring the wire harness up tonight (that was fun…) I also checked the floats in the carbs to make sure they were working correctly before I put them back onto the bike. I would like to let everyone know how much I hate mating those rubber gaskets up to the carburetors from the air box, it took me at least 30 minutes to make sure they were on properly and sealed.
I put the right clip-on back on temporarily so I could use the kill switch, and starter button and also just sat the gauges on as well and hooked them up. I turned the key on, and the gauges light up, I was pretty excited, so I pushed the starter button… It did nothing. So I checked all of the connectors to make sure they were properly mated, and tried again… nothing… So I was sort of flustered at this point. I was like well the other clip-on only has the head light, and the horn on it… why would it need to be hooked up?!?! But I tried it anyway, bolted that thing on and clipped the 2 units together. Turned the key back on and pushed the starter button, while I held the choke in with my other hand. VROOMM!!!! I had only pushed the button for about a half of a second and it fired right up! (It never started like that before and it’s like 40f outside so it’s cold) I left off the choke after like 5 seconds and the bike idled down to about 1200 rpm’s and sat there happy as could be.
I let it warm up a little bit, and checked the throttle response it seems much much more responsive than before. It had issues bogging, and flat spots.

I would also like to note that with the slip-ons off the bike, it sure is loud


I need to finish painting the clip-ons and do some wire management, so I'll be cleaning that stuff tonight.

I took these two pictures right after I started the bike. As you can tell the gauges are just sitting on their cage, and the clip-ons are just sitting on there as well. no clutch cable, choke, or throttle cables are hooked up.

[n3rv]

Lookin' sweet man.

On a related note, can we start taking wagers as to how many parts will be left over when he's done? 

Only the parts that I choose to leave off I'm loosing a few odds and ends for visual appeal.

[n3rv]

Nice bike. What kind of paint are you using. Do you need special paint for the fairings, special primer? Was thinkin about painting mine as well....

On the frame I'm just using Krylon Primer and Black gloss with zinc. I've used these two products before together on previous jobs and with proper prep work, and painting condidtions they will work very well, are very durable, and look almost as good at a base coast / clear coat professional job.

As for the plastics, I haven't done alot of research into them as of yet, prep work will be normal. I've heard different opinions on primers from just normal water based dupli or ppg paints, or epoxy primers from the same guys. I'll be sure to read up alot and get some opinions from painters on what I should use. I will be doing the painting my self, in a paint booth with our paint guns here at the house. So I'll be doing all the work my self, like the rest of the bike.

It sure is nice to have all the stuff on hand since my father does resto work as a hobby and I grew up with this stuff.