Getting around the problems with changing the front end. - Ex-500.com - The home of the Kawasaki EX500 / Ninja 500R
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post #1 of 22 (permalink) Old 9-24-2019, 4:20 AM Thread Starter
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Getting around the problems with changing the front end.

Curve the radiator
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post #2 of 22 (permalink) Old 9-24-2019, 5:44 AM
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You have more guts than I do.
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2006 Ninja500R Purchased new July 2006; 0 miles. Miles as of January 2019; 102,137. It's a GO bike, not a SHOW bike.
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post #3 of 22 (permalink) Old 9-24-2019, 1:44 PM
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How did you do it? What front end are you changing to?

'90 EX-5R w/ 2nd gen forks, Fox shock, aftermarket Ninja 250 wheels, 04 GSXR tail, undertail exhaust w/ Harley mufflers.
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post #4 of 22 (permalink) Old 9-24-2019, 8:12 PM
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Nice! I assume you fabricated new curved framed pieces and bent the core to them?
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post #5 of 22 (permalink) Old 9-25-2019, 2:47 AM Thread Starter
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I’m building up a gen 1 with a Ducati st2 front end, better riding position, 17’’ front wheel, better brakes and suspension. The radiator is the original one, I used a fine cutting disc and cut small grooves into the top and bottom plate being careful not to cut into the core. Then gently reshaped it over a barrel. The st2 has less fork offset than the ex, so with the suspension under load the wheel would otherwise hit the radiator
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post #6 of 22 (permalink) Old 9-25-2019, 10:31 AM
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Holy Cow that front end is off the hook! You should think about gusseting/bracing the frame since that front end is going to flex less than the stock front end, which will transfer those loads to the frame- head stock/neck area for sure, swingarm pivot area as well if you're going that far. Those are FOG recommendations as he has seen the frames break at those spots after hard race use.
Great job on the radiator- looks professionally done. Did you weld the top and bottom plate after cutting and bending?

'90 EX-5R w/ 2nd gen forks, Fox shock, aftermarket Ninja 250 wheels, 04 GSXR tail, undertail exhaust w/ Harley mufflers.
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post #7 of 22 (permalink) Old 9-25-2019, 11:28 AM
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He should be putting the ex engine in the Ducati frame

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post #8 of 22 (permalink) Old 9-25-2019, 6:32 PM Thread Starter
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True, it’s not a race bike, the swing arm is off a zr 750 also the rear wheel, so 5.0 inch rim, and 160 rear Tyre. Gets rid of the skinny 16’’ rear wheel. Shock is sv 650, gen 2 pivot linkage.
Fog has help to stiffen things up with the solid engine mounts. I still want the bike to be fundamentally a gpz. I’m sure it will still wobble, but that’s half the fun.
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post #9 of 22 (permalink) Old 9-25-2019, 7:37 PM Thread Starter
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Here’s the rear end
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post #10 of 22 (permalink) Old 9-25-2019, 7:41 PM Thread Starter
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I didn’t Re weld the radiator there’s heaps of strength in the core, I looked around for one off another bike but nothing seemed right.
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post #11 of 22 (permalink) Old 9-25-2019, 10:22 PM
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Oh oh....

An EX motor in a Cagiva Mito frame caused enough consternation around here.

I finally figured out why I like Ducatis: With their exhaust note and dry clutch, they sound almost like a Guzzi!
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post #12 of 22 (permalink) Old 9-25-2019, 10:27 PM
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If you want a cheap, big piston rebound adjustable shock, a '99-'05(?) ZR-7S bolts right on. The only one I've found that does. Same length, same bolt sizes. It clears the Gen1 swinger as well. Top mount is 2mm narrower, so a washer or two and you're good to go.

I finally figured out why I like Ducatis: With their exhaust note and dry clutch, they sound almost like a Guzzi!
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post #13 of 22 (permalink) Old 11-8-2019, 2:50 PM
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Quote:
Originally Posted by kiwigpz View Post
Hereís the rear end
Is the swing arm a straight swap? I'm looking at doing something like yours on my next build.
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post #14 of 22 (permalink) Old 11-15-2019, 3:15 PM Thread Starter
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No, not a straight swap. Quite a bit of modification to get this swing arm to work. The pivot axel is a lot larger than the standard one, also the ZR one is wider so has to be trimmed down to fit the frame. The suspension pivot connection is in the right place so you can at least use the standard suspension linkage.
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post #15 of 22 (permalink) Old 11-22-2019, 10:35 AM Thread Starter
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Here is a pic of the swing arm linkage connection
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post #16 of 22 (permalink) Old 11-22-2019, 2:07 PM
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Super cool. I'm gonna swap my front end with a ZX6R eventually, so this thread gives me some motivation. Are you doing body mods too, or will the original fairings go back on?

Paul

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post #17 of 22 (permalink) Old 11-28-2019, 11:07 PM Thread Starter
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I want the bike to still look reasonably original, so standard gen 1 bodywork with the Ducati front guard and Airtech rear undertray to eliminate all the ugly bits. The project always seems to have a mind of its own. One change means I have to shift something else around.
I fitted a steering damper where the radiator overflow sits, so had to get a new alloy overflow tank sat in next to the battery. Stuff like that. I’m running pod filters and dynojet kit which has left a good amount of space where the air box used to be. I’ve only just gone through the engine and got that back in, so still need to finish fitting up the exhaust, then more stuff will fall into place. The engine has a mild tune, ported head, yoshimura street cam profile, lobe centred, new rings, camchain and tensioner. Head and cylinder skimmed, just to mate up the surfaces, and a valve job. Paint is black with gold logos and pin stripes. I will post more photos as it comes along. Cheers
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post #18 of 22 (permalink) Old 11-28-2019, 11:12 PM Thread Starter
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This is where it’s at
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post #19 of 22 (permalink) Old 12-3-2019, 12:45 AM Thread Starter
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The pipe is on and now I can fit up the radiator.
I had to use an aftermarket fan as the standard one hits the motor, all fits pretty sweet and plenty of room for the front wheel under brakes
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post #20 of 22 (permalink) Old 12-3-2019, 12:48 AM Thread Starter
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The zr swing arm is also works well gives a extra inch in length, it’s more rigid and uses larger axel and swing arm pivot
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post #21 of 22 (permalink) Old 12-3-2019, 4:31 PM
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Quote:
Originally Posted by kiwigpz View Post
True, itís not a race bike, the swing arm is off a zr 750 also the rear wheel, so 5.0 inch rim, and 160 rear Tyre. Gets rid of the skinny 16íí rear wheel. Shock is sv 650, gen 2 pivot linkage.
Fog has help to stiffen things up with the solid engine mounts. I still want the bike to be fundamentally a gpz. Iím sure it will still wobble, but thatís half the fun.
Check into the adjustable rebound shock from the '99-'05 ZR-7S. 12.5" long, it bolts right on. You will need a 2mm thick washer at the top mount, since for some inexplicable reason, is 2mm narrower than other Kawi shocks. Clearance is not an issue, even on Gen1 swingers. Gen2 has even more room in this regard. As I recall, the spring rate is about 450lbs/inch, just about what the EX/GPz needed in the first place.
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I finally figured out why I like Ducatis: With their exhaust note and dry clutch, they sound almost like a Guzzi!

Last edited by po18guy; 12-3-2019 at 4:33 PM.
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post #22 of 22 (permalink) Old 12-4-2019, 2:49 AM Thread Starter
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I have an sv 650 rear shock in there at the moment, it gave me another inch in ride height.
If that’s not working out I will check it out cheers
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