wont rev past 5500 ? '93 model - Page 4 - Ex-500.com - The home of the Kawasaki EX500 / Ninja 500R
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post #76 of 99 (permalink) Old 12-20-2019, 4:22 PM
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Quote:
Originally Posted by DannoXYZ View Post
I have hunch on tach-signal interface. Inspect that tach-signal wire from tach to its source when you get chance.
I beleive the Tach signals are active low so a loose wire might cause erattic peaks in the positive, plus I think the OP talked about the bikes performance and not hitting the (insert your color of choise here) power band.

1993 Teal/White EX500 6K First Street Bike
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post #77 of 99 (permalink) Old 12-23-2019, 7:23 AM Thread Starter
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old coils be reading liek:
2.4 primary
11 K secondary


New:

2.6 primary
13k secondary


which wire is the tach signal? or can i just unplug both wires and go at it?

i shortened the wires from the coils to the plugs bc they were stupid long. resistance seems fine imo.

UPDATE she Free rev's fine and great! my issue seems to be under load. i was able to get her up to 8k rpm's or so over the weekend. above 5500/6k she is kind of hesitating. it's still climbing but almost like there's a slight stutter to it. not a smooth pull like it should be. progress regardless.
i did get my twin delete in and install the plates, it does look clean and make plug access easier, so that's cool.

Once the bike finally warmed up (takes quite a while, granted it's also mid - high 30's where im at) i took it out. almost as soon as i start to get moving it cools down a lot haha cant keep this thing warm enough to test ride.

im up to about 2 ish turns out on each pilot jet. i understand the cold weather plays a factor and i may need to adjust in the spring/summer when it's 80-90* out

MERRY CHRISTMAS!

'93 ex500, upjetted and piped

RZ 350, ktm300 xc-w, ls650 hardtail bobber, '78 70cc malossi honda hobbit mini gp race bike
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post #78 of 99 (permalink) Old 12-23-2019, 11:03 AM
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(SNIP)
UPDATE she Free rev's fine and great! my issue seems to be under load. i was able to get her up to 8k rpm's or so over the weekend. above 5500/6k she is kind of hesitating. it's still climbing but almost like there's a slight stutter to it. not a smooth pull like it should be. progress regardless.
i did get my twin delete in and install the plates, it does look clean and make plug access easier, so that's cool.

Once the bike finally warmed up (takes quite a while, granted it's also mid - high 30's where im at) i took it out. almost as soon as i start to get moving it cools down a lot haha cant keep this thing warm enough to test ride.

im up to about 2 ish turns out on each pilot jet. i understand the cold weather plays a factor and i may need to adjust in the spring/summer when it's 80-90* out

MERRY CHRISTMAS!
It requires much less throttle opening/fuel/airflow to rev when there's no load, so it's not really an indication of anything.

Still seems like the slides are not lifting properly.

I think you said it had different Main Jets. Have you tried going back to stock? Typically the stock Mains are rich anyway. You may have way too much fuel when you start to progress to the Main.

Have you looked at the plugs lately?

Block off part of the radiator to keep the temps up.

EDIT: You are positive the Needle Jets are in position correctly?

Last edited by jkv357; 12-23-2019 at 4:40 PM.
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post #79 of 99 (permalink) Old 12-24-2019, 11:24 AM Thread Starter
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Fairly certain the needles are in correctly... they went in the same way I took em out.

Here's a video. I'm about 80-90% throttle. Hopefully you can hear the breakup over the windnoise... sorry phone quality

https://youtu.be/pvtPr2Z-4fI

'93 ex500, upjetted and piped

RZ 350, ktm300 xc-w, ls650 hardtail bobber, '78 70cc malossi honda hobbit mini gp race bike
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post #80 of 99 (permalink) Old 1-2-2020, 7:55 AM Thread Starter
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seems almost like its getting better and better every time i ride it... and the warmer weather is good too lol

anyone take a look at the vid ?

'93 ex500, upjetted and piped

RZ 350, ktm300 xc-w, ls650 hardtail bobber, '78 70cc malossi honda hobbit mini gp race bike
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post #81 of 99 (permalink) Old 1-2-2020, 8:32 AM
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yes I have It sounds exactly like my project bike did last year. while experimenting with the non stock set up. never ran 100% but I'm afraid I have no idea what cured it as I did the classic all in one go swap over. changed mine to COPS over iridium plugs. set all the carbs to stock and fitted a KN filter with the airbox mods still on. no idea what your set up is. but somethings not right.
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post #82 of 99 (permalink) Old 1-2-2020, 11:08 AM
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If your needles have the c clip I would measure the stock vs clip needle height and try to match, might be flooding in wot. I might have some stock needles form a old carb rebuild kit and I can look tonight and measure in the am.

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post #83 of 99 (permalink) Old 1-3-2020, 8:16 AM Thread Starter
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Quote:
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If your needles have the c clip I would measure the stock vs clip needle height and try to match, might be flooding in wot. I might have some stock needles form a old carb rebuild kit and I can look tonight and measure in the am.

that'd be cool! last time i went through the carbs the clip was in the third position and i moved it to the second position. maybe i'll hit it again move it up top to the #1 spot

'93 ex500, upjetted and piped

RZ 350, ktm300 xc-w, ls650 hardtail bobber, '78 70cc malossi honda hobbit mini gp race bike
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post #84 of 99 (permalink) Old 1-3-2020, 10:38 AM
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I only have 4x zx600e allballs needles unless there in my shed, I thought I got a full kit for the 500. I know someone elde on here will chime in with a measurement. I checked part numbers and they were different. Im trying to blow out my parts stock so I may still come accross some but dont hold your breath.

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post #85 of 99 (permalink) Old 1-8-2020, 11:15 AM Thread Starter
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i moved the clips up to the top most position... confirmed all my hose clamps were tight for no air leaks but did notice i still had a hole in the airbox from when i deleted the Twin system, so i plugged that...
when i moved the clip position from #2 to the #1 (top most) spot, i noticed the left carb needle was missing the two washers that used to sit on top of the clip. they were on the ground of the inside of the slide around the base and not on the hat of the needle if you will
with it being up top now, i just removed the washers (2 from each side) entirely. it fired right up and ran a little better - prior to this when i would turn the choke all the way ON if you will, the rpm's would jump up to like 4k or so... and it was SUPER touchy. now it seems like it would hit maybe 2000 rpm at most. however it was snowing hard here last night and the road was pretty wet... not going to take it out to test in that.

will report back

'93 ex500, upjetted and piped

RZ 350, ktm300 xc-w, ls650 hardtail bobber, '78 70cc malossi honda hobbit mini gp race bike
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post #86 of 99 (permalink) Old 1-9-2020, 7:12 AM Thread Starter
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soooo... now it's good up top, like above 6500 or so, pulls well. but down low it's hesitant, like a lot. i guess im getting close. gonna play with the a/f screws a bit and see what i can make happen

anyone have a good tool they use ? the screws are in a shitty spot :/
ive been trying to find a really small flathead to use or even the tip of a universal screwdriver

'93 ex500, upjetted and piped

RZ 350, ktm300 xc-w, ls650 hardtail bobber, '78 70cc malossi honda hobbit mini gp race bike
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post #87 of 99 (permalink) Old 1-9-2020, 9:14 AM
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Just add a 1/4 ratchet to bit adapter or some layers of electrical tape.


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post #88 of 99 (permalink) Old 1-9-2020, 10:10 AM
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ya think after 87 post you would just put the stock jets back in

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post #89 of 99 (permalink) Old 1-9-2020, 10:23 AM Thread Starter
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Quote:
Originally Posted by fog View Post
ya think after 87 post you would just put the stock jets back in

FOG

wouldnt that require me putting the stock exhaust back on ? which i dont have, nor the jets.... unless you got the hookup ?






Edit: Hey at least im not one of those guys on here for a week or two then never log on again

'93 ex500, upjetted and piped

RZ 350, ktm300 xc-w, ls650 hardtail bobber, '78 70cc malossi honda hobbit mini gp race bike
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post #90 of 99 (permalink) Old 1-9-2020, 11:31 AM
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I told you way back when do the fog mod, or at least read it. stock jets work fine with the tooter.
DID you ,can you check the cam timing? almost all are retarded, but don't think it can skip time and still run. Valves hit pistons.

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Last edited by fog; 1-9-2020 at 11:34 AM.
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post #91 of 99 (permalink) Old 1-9-2020, 11:54 AM
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I cut the excess handle meterial off of a small craftsman flathead, I ran mine between 2.5 and 3 turns out.

https://www.google.com/url?sa=i&url=...AAAAAdAAAAABAD

1993 Teal/White EX500 6K First Street Bike
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post #92 of 99 (permalink) Old 1-9-2020, 3:05 PM
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wouldnt that require me putting the stock exhaust back on ? which i dont have, nor the jets.... unless you got the hookup ?

Edit: Hey at least im not one of those guys on here for a week or two then never log on again
listen to FOG and take notice. no jets other than stock are right. 130#mains 35#pilots too big it runs rich too small it runs weak. only the correct needles N36N have the right profile non of the clip type needles have the right profile [don't ask how I know] and the height is set as it's non adjustable. I have two GPZ50's [EX500] one has stock pipes the other a Motad 2 into 1 both run just the same with the idle and pilots adjusted. both bikes have the fog mod and KN filter.

both bikes rev evenly up to 6/7k at a sombre rate [that's normal] then take off like a screaming banshee to the red line. except in top 6th were the top revs are limited by the gearing only reaching 9.5k [117mph] but that is fast enough for me thanks.
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post #93 of 99 (permalink) Old 1-9-2020, 3:35 PM
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on 12/5 post #22 of this thread, refurbs were suggested (with stock jetting included)
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post #94 of 99 (permalink) Old 1-10-2020, 7:10 AM Thread Starter
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Quote:
Originally Posted by ducatiman View Post
on 12/5 post #22 of this thread, refurbs were suggested (with stock jetting included)

valid. lemme get a hold of some stock jets and i'll check back in. im getting good at having the tank off and these puppies off in maybe 5 mins max now


edit: just ordered... says 7 days shipping. hopefully by mid/late next week i'll have em and can update

'93 ex500, upjetted and piped

RZ 350, ktm300 xc-w, ls650 hardtail bobber, '78 70cc malossi honda hobbit mini gp race bike

Last edited by Sh00bs; 1-10-2020 at 7:31 AM.
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post #95 of 99 (permalink) Old 1-10-2020, 9:26 AM
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uh, the term stock jetting includes needles. N36N ...you order them too? (sticker shock)

Again, the #72 refurbs would have offered quick, efficient solution over 30 days ago.

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post #96 of 99 (permalink) Old 1-10-2020, 9:52 AM Thread Starter
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Quote:
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uh, the term stock jetting includes needles. N36N ...you order them too? (sticker shock)

Again, the #72 refurbs would have offered quick, efficient solution over 30 days ago.



do i have any reason to believe i dont have the N36N needles in there now ?



agreed, but im stubborn and like to try to make things work as is before putting money out

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post #97 of 99 (permalink) Old 1-10-2020, 10:54 AM
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the stock needles have a fixed head, not circlips

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post #98 of 99 (permalink) Old 1-10-2020, 11:36 AM
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^ bingo

you had a jet kit in there, or some remnants thereof. Factory supplied 35 pilots, 130 main and N36N needles aka "stock jetting"

************************************************** ****************************************
an aside for discussion purposes .....when encountering jet kitted carbs I become quite suspicious, a common misconception that "more fuel = more power" thus folks have a tendency to grossly overfuel, even "modding" to accomplish.

I recently found a set of jet kitted 250 carbs with *correctly marked* pilots but upon indexing (measuring) them, I found them drilled out to the equivalent of 2 sizes larger. The owner was complaining of running rich to the point of fuel stink out the exhaust, and still running with pilot screws *closed*. Between the combination of oversized mains, drilled pilots, shimmed thin kit needles the thing was swimming in fuel.

Point being, you never know what prior hands have done (or not done) until close component evaluation....and what a part is marked should not be assumed correct until confirmed. Some of the "mods" are actually destructive... taking a drill bit to brass float valve seats comes to mind, or hammering them in attempt to remove (they are not replaceable) These destroyed carb bodies are unrepairable....trash.

Sorry, rant over.
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post #99 of 99 (permalink) Old 1-14-2020, 10:22 AM Thread Starter
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realized i didnt order the needles... anyone have some laying around before i spend about $45 on fleebay ?

'93 ex500, upjetted and piped

RZ 350, ktm300 xc-w, ls650 hardtail bobber, '78 70cc malossi honda hobbit mini gp race bike
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