Hi all - new 500r - Ex-500.com - The home of the Kawasaki EX500 / Ninja 500R
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post #1 of 22 (permalink) Old 1-2-2020, 5:16 PM Thread Starter
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Hi all - new 500r

Hi Everyone - Glad to find this forum and all the valuable knowledge here! I've been away from riding for many years but got the bug again. I've always liked the EX500 but never had one - reliable, easy to work on, efficient, quiet, not too fast, fairly upright riding position.

I recently bought a 2003 500r. It's blue/gray with dark gray rims, 5,900 miles, totally stock. I think it was babied for most of its life but then neglected and left outdoors the past year.

The bike was able to start and sounded fine, but only with the choke on. It's kind of a miracle it could run at all with amber colored fuel in freezing temps. Plus, I noticed later that a mud-wasp had built a nest in the little drain hole for the right spark plug, so at some point that area filled with water and rusted the plug to oblivion. The inner plug cap retaining ring had turned to dust so it was just flopping around on top of the plug.

Anyway, I've had a lot of fun stripping everything off the bike for a total restoration this winter. I took the airbox out - the original air filter was vaporizing into a fine yellow dust. And I just cleaned the carbs, which were in good shape except of course for the pilot jets and idle circuit.

Right now I plan to keep everything stock except I picked up a pair of OEM 650r mirrors so I can see past my elbows. Can't wait for Spring!
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post #2 of 22 (permalink) Old 1-3-2020, 12:46 PM
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Quote:
Originally Posted by slower View Post
Can't wait for Spring!
#comeonspringdammit there, fixed that for ya'

and welcome

“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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Last edited by ducatiman; 1-4-2020 at 2:55 PM.
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post #3 of 22 (permalink) Old 1-4-2020, 11:26 AM
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Welcome to the forum and welcome back to riding! It sounds like you know your way around a bike. Whereabouts in NH are you? I'm in SE MA. Close enough to meet up for a ride sometime?
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post #4 of 22 (permalink) Old 1-4-2020, 12:17 PM
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Looks like you rescued the bike just in time. Nice find.

I also an EX-500 from a life outside. The bike was surprisingly nice with the exception of the chrome on the mufflers which was essentially knackered. Yours look to have faired much better in its time outside.

Come on Spring, I have 2 boys itching to learn to ride a street bike.

2007 Kawasaki EX-500 Ninja
2003 Honda Goldwing
2001 Honda VFR 800
2000 Kawasaki KDX 200
1999 Ducati 996 BiPosto
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post #5 of 22 (permalink) Old 1-4-2020, 6:53 PM
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2006 Ninja500R Purchased new July 2006; 0 miles. Miles as of January 2020; 108,827 . It's a GO bike, not a SHOW bike.
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post #6 of 22 (permalink) Old 1-4-2020, 7:51 PM
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Welcome to the forum!
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post #7 of 22 (permalink) Old 1-13-2020, 10:52 PM
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Welcome.
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post #8 of 22 (permalink) Old 1-22-2020, 9:10 AM
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Hi. It's nice to see you here
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post #9 of 22 (permalink) Old 1-22-2020, 2:41 PM Thread Starter
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Thanks for the welcomes. I've read hours worth of posts here already. Pretty much every question I've had has already been answered! Not surprising, though, this list goes way back. Amazing to see some of you with bikes bought brand new and now over 100K miles. I wonder what the world record is for the ex500 on an original engine.
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post #10 of 22 (permalink) Old 1-30-2020, 12:35 PM
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Drop a picture of the installed 650 mirrors when you get the chance, interested to see how it looks!

Stay on 2!
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post #11 of 22 (permalink) Old 1-30-2020, 4:23 PM Thread Starter
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Drop a picture of the installed 650 mirrors when you get the chance, interested to see how it looks!

I definitely will. Can't wait to put everything back together in a couple months. I imagine the mirrors will look something like this.


I also picked up a ZX-12R left control, with the hazard light switch. Seems like it could come in handy, especially if I'm ever invited to be in a parade. haha.
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post #12 of 22 (permalink) Old 2-3-2020, 11:56 AM
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Quote:
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Quote:
Originally Posted by Sherman8rr View Post
Drop a picture of the installed 650 mirrors when you get the chance, interested to see how it looks!

I definitely will. Can't wait to put everything back together in a couple months. I imagine the mirrors will look something like this.


I also picked up a ZX-12R left control, with the hazard light switch. Seems like it could come in handy, especially if I'm ever invited to be in a parade. haha.
Hahaha I wasn’t expecting that!

Stay on 2!
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post #13 of 22 (permalink) Old 2-6-2020, 3:49 AM
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Bro how much did you pay? There's a dude in this forum that has a set of perfect ready to install carbs perfect cond for $220. here it is. https://www.ex-500.com/50-carburetor...bset-72-a.html



I dunno if you are gonna attempt the flarbolator yourself but if not $220 not bad.? You know.

how did your flarb cleaning turn out?


Insurance is $75/ year with progressive or like 135 with all the bells and whistles in a geico policy.



Have you checked the valve adjustment? Also are you thinking about new brake line? Bled the brake sys?



Did you change out plugs? GO WITH NGK see(https://www.ex-500.com/14-engine/140...-plug-fiy.html)


If not change out then clean and gap at 3k Either way excited to hear more!!
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post #14 of 22 (permalink) Old 2-6-2020, 1:08 PM Thread Starter
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Bro how much did you pay? There's a dude in this forum that has a set of perfect ready to install carbs perfect cond for $220. here it is. https://www.ex-500.com/50-carburetor...bset-72-a.html
I paid $400. The guy had moved on to a GSXR and his wife gave him a 2 day ultimatum to get rid of the EX500, so I was in the right place right time.

Quote:
how did your carb cleaning turn out?
The carbs needed some cleaning but are in great shape. ducatiman's are flawless and a good deal at $220 for anyone who doesn't want to do their own. On one hand I'm pretty happy that nobody touched the bike in 17 years - nothing is missing, messed up, tweaked, or molested....but on the other hand it needs a lot of work. Buy hey, it's winter! And I like working on motorcycles as much as I like riding them, so that's fine with me.

Quote:
Insurance is $75/ year with progressive or like 135 with all the bells and whistles in a geico policy.
Yeah insurance is super cheap for the EX.

Quote:
Have you checked the valve adjustment? Also are you thinking about new brake line? Bled the brake sys?
Yes, I did the valves. Exhausts were tight, intakes were good. (5,900 miles) I still need to clean the entire brake system. Not sure what I should do for lines - leave as-is? new rubber lines? or new braided? I would love to make my own.

Quote:
Did you change out plugs? GO WITH NGK see(https://www.ex-500.com/14-engine/140...-plug-fiy.html)
Yes, new DR9EA plugs, caps, and wires.

Quote:
If not change out then clean and gap at 3k Either way excited to hear more!!
Thanks!
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post #15 of 22 (permalink) Old 2-8-2020, 2:51 AM
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Manual says change at 4 years change them so you are running on 17 year old lines that sat outside last year.


I feel like Galfer Spiegler venhill are the best Galfer are the most expensive out of them all but they claim their quality is best







Ot you can take your chances with this one for 70 something https://www.ebay.com/itm/Stainless-B...0AAOSwTGZcyOSz See why you should avoid them here https://www.ninjette.org/forums/showthread.php?t=260224





I RECOMMEND THIS a set ofrom galfer https://www.ebay.com/itm/Galfer-Stai...4AAOxyRhBSqnWf





Well new rubber oem lines for the front are like $75-110 https://www.ebay.com/sch/i.html?_fro...temCondition=3


rear $75 https://www.ebay.com/sch/i.html?_fro...dition=3&rt=nc
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post #16 of 22 (permalink) Old 2-8-2020, 8:43 AM
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another brake line alternative....remove them, bring to a local hydraulic house. I've been dealing with an Aeroquip Hydraulic dealer for many years....they build in SS perfectly using your OEM sample....Kaw, Honda, Ducati, no matter.
Efficient, long lasting, perfect fit, economical, convenient...walk in/ walk out, no waiting.
Never had an error or failure in approx 35(?) years on various motorbikes.
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post #17 of 22 (permalink) Old 2-15-2020, 10:04 PM
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Welcome to the forum. You'll find some great information here. Also, thanks Duc, I hadn't even considered a local place. Just found out I drive by one every morning after work. The walk in walk out service sounds like a great idea.

Last edited by Elsevere; 2-15-2020 at 11:15 PM.
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post #18 of 22 (permalink) Old Yesterday, 11:24 AM Thread Starter
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Thanks for the brake line tips above, ducatiman and tigerepair. Going to local shops brings back good memories hanging out and working on stuff with my grandfather. No matter what he needed he'd try to have it made locally. We'd drive all over finding machine shops, welders, upholstery repair, etc. It usually took a full day to do anything because he liked to talk and get a tour of the places we went.


One place I was buying parts sells Russell SS lines. If anyone has positive/negative experience with these, let me know.
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post #19 of 22 (permalink) Old Yesterday, 12:57 PM
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Russell lines have SAE fittings... a ROYAL PIA.
My local hydraulic house won't make brake lines, IF you tell them they're brake lines. Liability issues. Tell them they're oil cooler lines.



I make my own lines now. a pair of 30" lines is $20... less than one Russell SAE banjo bolt.
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post #20 of 22 (permalink) Old Yesterday, 12:59 PM
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If you make your own brake lines they have to be coated to be DOT.
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post #21 of 22 (permalink) Old Yesterday, 1:19 PM
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I make my own lines now. a pair of 30" lines is $20... less than one Russell SAE banjo bolt.
method and equipment used please?

“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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post #22 of 22 (permalink) Old Yesterday, 10:48 PM
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You'll need some AN3 hose and fittings.


I usually use a die grinder to cut off the hose, and I made a little anvil that fits into the olive to push it down.


You can buy 50' of line on Aliexpress for $50. Watch out for the cheapo fittings though.
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