Finished Project - Ex-500.com - The home of the Kawasaki EX500 / Ninja 500R
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post #1 of 12 (permalink) Old 5-14-2019, 9:28 PM Thread Starter
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Finished Project


I finally finished my 2000 Kawasaki Ninja 500 rebuild. This is my first motorcycle and first project. It was a long road, but I can finally reap the rewards. Here is a list of all the things I have done to the bike that I can remember.

*New rotors front and back
*All Balls wheel bearings front and back
*Rebuilt brakes front and back
*New brake pads front and back
*Three wire speed sensor
*New Michelin Pilot Street Radial tires
*Cut fork springs and added spacers
*Rebuilt forks
*Digital gauge
*New headlight with led running lights/turn signal upgrades
*All Balls steering stem tapered bearing
*Denali sound bomb horn
*Rebuilt carbs
*Valve adjustment
*New battery
*Flasher module
*CoP ignition coils
*Relocated electronics under seat
*FOG mod (air box hole, K&N filter, carb adjustment)
*FOG bones
*SV-650 shock
*RK racing chain
*New handlebar grips
*Bar end folding mirrors
*New throttle cables
*Shorty levers
*LED taillight w/ integrated turn signals
*Alarm system
*Various frame modifications for under seat storage compartment
*Media blast and paint entire bike
*New radiator
*New pipes
*Oil and filter change
*New upholstered seat
*New thermostat
po18guy, jorge moros, bpe and 3 others like this.
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post #2 of 12 (permalink) Old 5-14-2019, 10:24 PM
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Holy chit!!! Great job!!! Looks awesome!!!
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post #3 of 12 (permalink) Old 5-14-2019, 11:05 PM
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Well done! Did the SV650 shock swap right in with no other mods besides he FOG bones? How does the ride feel with it, versus the stock shock?

Paul

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post #4 of 12 (permalink) Old 5-15-2019, 8:55 PM Thread Starter
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The SV650 shock went in easily with the FOG bones. No other modifications were needed. I can not compare it to the stock shock because when I purchased the bike it did not have the stock shock on it. I'm not sure what shock it was, but it felt too soft for me. Between the SV650 shock and the stiffer front end, it feels much better. If you do decide to add the shock and FOG bones, I would take the center stand off as it will no longer support the bike due to the increased height. I had mine on the center stand with a board underneath and it tipped over.
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post #5 of 12 (permalink) Old 5-17-2019, 10:46 AM
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Right on, thanks.

Paul

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post #6 of 12 (permalink) Old 5-17-2019, 6:09 PM
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Nice! That's a lot of labor there. The paint looks great, as does the overall look, and with all the little things you did, I bet it rides as nice as it looks. Congrats and thanks for sharing this with us!
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post #7 of 12 (permalink) Old 7-10-2019, 10:55 AM
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How's the headlight treating you? Where'd you get it? Whole build looks great!
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post #8 of 12 (permalink) Old 7-11-2019, 9:56 PM Thread Starter
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I bought the headlight cheap on ebay. The turn signal lights were garbage and were mounted very cheaply so I removed them and epoxied a PVC coupling to the headlight. I then put some LED signals inside a PVC end-cap which in turn slides into the PVC coupling. It turned out well and now I have LED turn signals. I also had to use Bondo on the headlight because the molding process left an ugly indented seam in it. I have about 400 miles on the bike since I installed it (an hour of which was in heavy rain) and it is working fine. If I had to do it over again though, I would spend the extra money on a headlight with a better build quality.
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post #9 of 12 (permalink) Old 7-16-2019, 12:59 AM
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Looks fantastic! Beautiful color! Just got my 09 back to running and I was really digging it without the fairings.....but yours looks awesome! Great job👍🏽

I'm a Ninja........................'09 Ninja 500R
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post #10 of 12 (permalink) Old 7-16-2019, 6:38 PM
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Great project!!!

What paint did you use for frame and wheels?
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post #11 of 12 (permalink) Old 7-21-2019, 11:08 AM
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Woow..
I can not believe this is GPZ 500S. CONGRATULATIONS


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post #12 of 12 (permalink) Old 7-21-2019, 11:19 AM
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very tasteful, love the red frame

“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....” quote Hunter S Thompson

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