100k The history of 1 EX - Ex-500.com - The home of the Kawasaki EX500 / Ninja 500R
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post #1 of 13 (permalink) Old 6-3-2019, 11:19 AM Thread Starter
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100k The history of 1 EX

Bought new in July of 2006.
Retail price at the time was $5700.
Using an add from a dealer 90 miles away that was selling for $5000 along with paying in full with cash, managed to get them to drop the price to $5000. I went to the dealer that was 90 miles away a couple of weeks earlier. They either sold out on their EX stock, or was pulling a classic "bait & switch" . At this time I'm in the market for an EX500, and not just some random bike that is in stock . The dealer I bought from was 20 miles away, as none of the closer dealers had an EX in stock. At the time of purchase, the salesman tried to confirm the $5000 price from the other dealer. As luck would have it, all their salesmen were out to lunch ( because I knew that they were not offering this deal any more [if ever]) . So they could not confirm one way or the other .


September 2018 I roll the odometer.




States ridden in, in no particular order:
Georgia
Alabama
Florida
North Carolina
South Carolina
Tennessee
Kentucky
Virginia
West Virginia


Routine maintenance done (approximate numbers):
Oil & filter change 52 times
Valve adjustment 15 times
Coolant change 16 times
Spark plug replacement 30 times
Air filter change 7 times
Air filter cleaning 20 times
Brake pad replacement (front & rear) 13 times
Fork oil change 4 times
Front tire replacement 7 times
Rear tire replacement 14 times
Clutch cable lube 50 times
Other cable lube 5 times (each)
Battery replacement 2 times
Valve cover gasket replaced 2 times
Drive chain lubed 250+ times
Drive chain replaced 12 times
Sprockets replaced 5 times
Fuel & vacuum lines replaced 6 times
Motorcycle spray can polish 24 cans



Other non-routine maintenance done:
Clutch cable replaced 1 time
Throttle cables replaced 1 time
Fork seals replaced 1 time
Unitrack rebuilt (all new bushings, seals, and pins) 1 time
Pressure plate, clutch springs, throw out bearing, clutch cover gasket replaced 1 time
Starter motor replaced 1 time
Clutch switch replaced 1 time
Starter clutch replaced (wasn't necessary) 1 time
Water pump mechanical seal and oil seal replaced 1 time
Carbs rebuilt 2 times
Carb boots and clamps replaced 1 time
All coolant hoses replaced 1 time
Radiator leak repaired with epoxy 1 time
Fairing cracks (including headlight housing) repaired with epoxy 15 times (never the same crack twice)
Exhaust gaskets replaced 1 time
A few hose clamps replaced 1 time
Headlight bulb replaced 2 times
Tail/brake light bulbs replaced 5 times
Dash light bulbs replaced 8 times
Front turn signal bracket replaced 2 times
Speedometer cable replaced 1 time
Front brake line replaced (ss) 1 time
Rear caliper rebuilt 2 times
Front caliper rebuilt 1 time
Pair system air valve replaced 1 time
Right front mirror replaced 1 time (someone backed into it and knocked it over)
Cams replaced 1 time
Front brake rotor replaced 1 time
Rear brake rotor replaced 1 time
Coils replaced 1 time
Spark plug wires replaced 3 times
Horn bracket replaced (due to speedometer cable guide breaking off) 1 time (after the 2nd one broke off, decided it was unnecessary)
Petcock rebuilt 1 time (rebuild failed)
Petcock replaced 1 time
Turn signal relay replaced 1 time ( wasn't necessary, bad diagnostics)
Total cost for maintenance over $10,000. Not as bad as it sounds divided over 146 months.






An important note:
Oil pump failure at 10,000 miles leads to complete engine rebuild at this time.
At no cost as the bike was still under warranty.

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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Last edited by bpe; 7-27-2019 at 7:47 PM. Reason: Have to edit as I remember
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post #2 of 13 (permalink) Old 6-3-2019, 12:54 PM
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WOW! Kudos and congratulations - thanks for sharing!

1993 EX500
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post #3 of 13 (permalink) Old 6-11-2019, 7:16 AM
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yeah kudos indeed I admire your record keeping and maintenance records. it's a pity more members don't write if only briefly a history of their bikes. to give some pointers to new owners as to what they can expect from their bikes and roughly how much it costs to keep the bike in good running order. I may start a thread on this very subject so as to not hijack this one. well done @bpe you deserve a medal.
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post #4 of 13 (permalink) Old 7-24-2019, 8:31 PM Thread Starter
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Post 100K maintenence

I wont be documenting the routine maintenance here, it would follow the pattern established above.

Non-routine items and procedures after 100,000 miles:

Battery 1

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 #5 of 13 (permalink) Old 7-24-2019, 10:49 PM
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You went through an awful lot of sparkplugs.


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post #6 of 13 (permalink) Old 7-25-2019, 4:05 AM Thread Starter
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Originally Posted by jackal View Post
You went through an awful lot of sparkplugs.
Because I change them every 4000 miles. And was changing them at a much more frequent interval a few years ago while diagnosing a running rich issue. So I guess technically a few of those changes should have been listed on the non-routine maintenance list.

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 #7 of 13 (permalink) Old 7-25-2019, 4:53 AM
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Wow, I tend to check on them around the 10'000 mile mark, but not necessarily change them.


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post #8 of 13 (permalink) Old 7-26-2019, 11:14 AM
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Holy smokes man, you ride ALOT. Great story, thanks for sharing!
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post #9 of 13 (permalink) Old 7-26-2019, 8:46 PM
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Quote:
Originally Posted by Snowkat79 View Post
Holy smokes man, you ride ALOT. Great story, thanks for sharing!
He sure does. One of the few of us who have rolled their odometers over. I hit that big number a few years back, still chugging along at 141,000 though I do need to pull the engine for a service. Keep an eye out next year for my 150,000 mile thread.

@bpe, In the next couple of years, you should start regularly inspecting the frame. I had to weld a crack around where the coolant expansion tank is and I suspect another crack may be hidden on the inside of the frame where I can't easily see.

1990 EX500 - 142,000 miles as of August 12th, 2019
1993 Ducati 900SS - The real canyon carver
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post #10 of 13 (permalink) Old 7-27-2019, 7:42 PM Thread Starter
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Quote:
Originally Posted by jackal View Post
You went through an awful lot of sparkplugs.
Quote:
Originally Posted by jackal View Post
Wow, I tend to check on them around the 10'000 mile mark, but not necessarily change them.
Spark plugs, that's nothing.
I also replace my drive chain every 10,000 miles, whether it needs it or not (a chain warrantied for 20,000 miles).
I replace my tires when there is at least 1mm of rubber above the wear bar, sometimes 2mm.

Quote:
Originally Posted by Saabnut View Post
In the next couple of years, you should start regularly inspecting the frame.
Been doing that for the last 13 years. No cracks to be found . And riding in the rain forest including riding in the rain on average at least 1 time a week, no rust anywhere on the frame. Not even on the areas where the paint has rubbed off to raw metal, from my pant leg constantly flapping on it . I think I can attribute this to the MC polishing ( I need to go back and edit in polish on the routine maintenance).
You do raise an interesting point. I should make a post list of the parts that have gone the distance and are still original, the ones that commonly fail on other bikes much, much earlier.

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 #11 of 13 (permalink) Old 7-29-2019, 7:59 PM
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Quote:
Originally Posted by bpe View Post
Been doing that for the last 13 years. No cracks to be found . And riding in the rain forest including riding in the rain on average at least 1 time a week, no rust anywhere on the frame. Not even on the areas where the paint has rubbed off to raw metal, from my pant leg constantly flapping on it . I think I can attribute this to the MC polishing ( I need to go back and edit in polish on the routine maintenance).
You do raise an interesting point. I should make a post list of the parts that have gone the distance and are still original, the ones that commonly fail on other bikes much, much earlier.
That's good you don't have any cracks yet. Mine can probably be attributed to the notoriously rough roads around where I live. If you have fairly smooth, well maintained roads around your area, you are much better off.

Speaking of high mileage concerns, my front brake master cylinder sprung a small leak about the 135,000 miles mark. Teardown revealed it wasn't the seals which had gone bad but rather excessive wear over time in the bore from the piston prevented the seals from doing their job. If you do decide to dig into yours at some point, know that you'll need very narrow circlip pliers and a new dust boot, they almost always rip upon removal.

As for original parts still working, that sure would be interesting. I'm harder on mine that you are on yours, so I've worn out some of the not-standard service parts. But, a few parts stood the test time, namely the voltage regulator. It was still working just fine when I pulled it well after the 100k mark and it was original. When I upgraded to gen2 suspension around 105k, the rear end was still sporting the original brake shoes. Original odometer still works too.
A good deal was actually still original on mine at 100k, aside from the engine. Once I upgraded the suspension though, that really made the whole thing more replaced parts than not

The one hilariously original part, in spite of the 3 engine swaps, is the valve cover. I've got Toddlamp's block-off plates on it and they really don't want to come off, so I've just continued to move the valve cover from engine to engine.

1990 EX500 - 142,000 miles as of August 12th, 2019
1993 Ducati 900SS - The real canyon carver
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post #12 of 13 (permalink) Old 9-1-2019, 9:12 AM
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I'm approaching 60k miles with hopes of going to 100k and beyond. So I'm looking up to you guys. That said, when I look at this list, I feel a bit heavy about what may await me: carb rebuilds, replacing starters, radiator leaks, not to mention cracked frames! As much as I love riding this thing I still consider switching to a bike that is easier to maintain, though I don't know what that bike would be.
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post #13 of 13 (permalink) Old 9-5-2019, 3:34 PM Thread Starter
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Quote:
Originally Posted by castorp View Post
As much as I love riding this thing I still consider switching to a bike that is easier to maintain
I would stick with the EX .

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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