ZeroFret's '04 500R Project Log - Page 8 - Ex-500.com - The home of the Kawasaki EX500 / Ninja 500R
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post #176 of 185 (permalink) Old 2-25-2019, 5:09 PM Thread Starter
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Ordered a 2000 ZZR600/ZX600J ignition coil set to do the CoP mod.
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post #177 of 185 (permalink) Old 2-25-2019, 6:53 PM
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For your naked style setup, I think you'll really like it. Gets those coils and bracket out of there for a nice, clean look. The right side coil bracket does have a metal loop to help keep the clutch cable lined up. You can either fab something up to replace it or, like what I did, chop down the the unused part of the old bracket leaving the clutch cable guide on. I gave the bracket a nice curve to it, hit the exposed steel with black rattle can and called it a day.

A note on doing the CoP mod, you really don't need much tail on the coil harness. The coil wires off the main harness reach pretty far, my CoP wires are only 2-3 inches long.
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1990 EX500 - 139,000 miles as of April 29th, 2019
1993 Ducati 900SS - The real canyon carver
2002 EX500 - Undergoing a full restoration
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post #178 of 185 (permalink) Old 3-5-2019, 1:24 PM Thread Starter
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Thought some of you might like to see some photos of my progress on this. I decided to ditch the chopped gas tank idea, as well as the grab bar that I had on there. This opened up the space to simply improvise it and shape it without restraint. I have a more round top-down profile now, that I think matches with the tank much better. Additionally, the side-view is taking on a sort of classic race profile, which I'm really liking. It's still "rough-carved" at this point, and will be further refined as I go.

My method here is expanding spray foam, which I will later coat with epoxy and fiberglass veil. I don't know yet if I'm going to use this "plug" to create molds for carbon fiber parts, or if I'm just going to reinforce and coat the plug until it is rigid enough to be a one-off part.

What do you guys think?
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post #179 of 185 (permalink) Old 3-7-2019, 5:39 PM
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What do I think? I think I can relate to that artistic madman inside of you! LOL!

Great job shaping those subtle contours. It'll look great as a finished body part.
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post #180 of 185 (permalink) Old 3-10-2019, 9:59 PM
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Terblanche, Tamborini, Bordi, Galuzzi....you're channeling all the great Italian designers.

Seriously...very "friendly to the eye", calm flowing lines in your mock up.

In Italian...she's a looka good....'ay Imma like-a.
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**Being shot out of a cannon will always be better than being squeezed out of a tube. That is why God made fast motorcycles, Bubba.... Hunter S. Thompson**


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post #181 of 185 (permalink) Old 3-12-2019, 12:45 PM Thread Starter
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Wow! Thanks for the compliments guys! Really means a lot.

Quick update: I've started the process of remounting the winker, CDI, reg/rec, tail light, and turn signals. Everything going well so far, though I need to fab a custom mounting plate for the tail light, and haven't the drill bits, or material yet. Should be easy enough to come by though. So that's the good news. The bad news is that I'm probably going to have to start all over on the foam shaping. Not to big of a deal really, since I should be able to get back to the same point with it fairly easily. I'm keeping the same profile for sure.

One question for you guys. I'd like to remount the starter relay, but the wires/cables connecting it aren't long enough to place it where I want it. So would there be any harm in extending the existing wires? If not, what's the best way to do that? I can solder very well, but so far my crimping skills aren't great.

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post #182 of 185 (permalink) Old 3-17-2019, 10:23 AM
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Did you find a solution to the bar end mirror problem? I was able to fit some bikemaster bar-ends on mine--over the weights--so long as I used a bit of shim (I made one out of plastic cut from a bottle). They were pretty good mirrors--gave a great vibe-free view too--but I busted them when I let the bike fall over on some gravel. I can look up the link to them if you like. I replaced them with some dual sport mirrors, which I also mounted as bar ends. These are more practical and they don't break when i drop the bike, but I admit they are a little unconventional on an ex500--especially as bar ends. Basically what I did was use a slightly longer bolt for the bar end weights, put a nylon spacer between the bar ends and the bar end weights, and mounted the dual sport mirrors onto the spacer. The mirror mounting stuff covers the spacer so it looks pretty clean.

I've been following what you've been doing with your bike with a lot of interest. The gauge cluster you did looks really clean. I hope you'll post some pics of the whole bike when you can.
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post #183 of 185 (permalink) Old 3-17-2019, 12:48 PM Thread Starter
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Thanks for the kind words. I'll definitely post a full-body shot when everything is done. Right now I'm just teasing little bits, so that the "big reveal" is more spectacular. :P

As far as the bar end mirrors situation, I dropped my HVMP weights off at a local machine shop some months ago, to have them turn a ledge down on each end, for the mirrors to clip on to. It's been a while actually, I should give them a call.

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post #184 of 185 (permalink) Old 3-18-2019, 11:27 AM
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I don't see an issue with getting longer wires to relocate the starter relay. The eyelets for those wires is a pretty standard size, they fit m6 bolts, so a run out to a motorcycle scrap yard for the same gauge wire ought to get you what you need.

1990 EX500 - 139,000 miles as of April 29th, 2019
1993 Ducati 900SS - The real canyon carver
2002 EX500 - Undergoing a full restoration
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post #185 of 185 (permalink) Old 5-14-2019, 11:27 PM Thread Starter
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Hey all, how's everybody been? I've been busy! Mostly with my new position as mechanic at the non-profit bicycle shop that I work at. But I've also been away from my EX while I waited for the shed/shop in my backyard to be installed. My gf insisted that it be a pro job, since it raises the value of the house she bought (I'm a freeloader, haha), and wow, was it worth the wait. Super nice new shop that I get free reign to work on my projects. I'll post some pictures here eventually, but in the meantime, follow my moto-dedicated account on Instagram @pandemoniumattachment.

I had an issue today, and I just need a sanity check from the experts. Finally got my bike into the new shop, and the smell of gas was overwhelming. Wasn't an issue even a week ago, but here it was. A quick inspection saw some leakage from the right side carb. I removed the gas tank, and drained the fuel from the carb bowls... or so I thought. Removed all the clamps and cables to pull the carbs out, and as I did so, a not insignificant amount of gas spilled out from that right carb, all over and into the engine. Argh! I sopped up every little bit of the mess that I could. Now, my question is, am I correct in figuring that it is the float needle that must have got stuck, resulting in a flooded carb? A good carb cleaning should eliminate the issue, right?

Paul

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