Hello! Got a Project EX500 - Ex-500.com - The home of the Kawasaki EX500 / Ninja 500R
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post #1 of 14 (permalink) Old 1-13-2020, 12:22 PM Thread Starter
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Hello! Got a Project EX500

I decided for 2019 I wanted to get a project of some sort. I've been following a bunch of Youtubers that rebuild salvage cars and I was all, "Damn, I can do that." Well what they don't tell you is how much everything costs. I think that with the recent popularity of these group of people the price of salvage vehicle (at least in my area) have skyrocketed! I really have a shoestring budget when it comes to projects but motorcycling is definitely my passion. It really has brought great joy in my life and is really important to me. Riding is amazing, gives a really liberating feeling.

Well anyway, I was hunting for a project car for awhile. Checking out salvage actions and such. My budget was like $1,000. I was constantly being outbid and just kind of gave up. I didn't want to buy anything that didn't have a following and would have to hunt for parts and tutorials. My first motorcycle was a 1994 Yamaha YZF 600R that I bought off of some dude for $900. It was totally trashed, the fairings where all busted up. Unfortunately that generation of bike was only produced for a couple of years and fairings where extremely hard to find. After awhile I had just sold it for $1000ish to someone. I got some wrenching in on that bad boy but I was mainly fixing and wanted something way more reliable. I was riding a 2003 BMW F650GS Dakar for awhile but sadly it got totaled in an accident. Now I have this F750GS, I do feel a bit spoiled by BMW bikes.

So finally I got this 1995 Kawasaki Ninja 500 off of someone on Craigslist for like $300. The guy bought this bike for his daughter and they promptly put racing tires on it. She was constantly dropping it (go figure). So she stopped riding all together. Kind of sad but eh to each their own. I just really wanted something to work on and the Kawasaki Ninja 500 was on my list. It doesn't start but I'm putting together the missing pieces.
This is what I know is missing:
  1. Throttle Cables
  2. Throttle Tube
  3. Clutch Lever
  4. Clutch Cable
  5. Start Button/Engine Kill Switch
  6. Petcock

I know I need to do these things:
  1. Battery
  2. Oil Change
  3. Spark Plugs
  4. Rebuild Carbs

Right now I just want to get the engine started and running before I start fixing the cosmetics and the other essential parts of the bike. I've set a budget, don't want to spend too much to get it going again. I've already ordered a new throttle tube. Just kind of waiting for everything else. One thing I've noticed is that my bike does have the CA emissions stuff on it. I would really like to get rid of it. I see talks about this PAIR system but a lot of links are dead and I'm unable to access to wiki for some reason.

If anyone has some pointers on where I should start that would be great! This would be my first time reviving a motorcycle from a deep hibernation.
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post #2 of 14 (permalink) Old 1-13-2020, 7:38 PM
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Welcome! We lost communication with the wiki during a software change last year. It's still accessible via Internet archives. There's an announcement at the top of most forum sections explaining how to access it.
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post #3 of 14 (permalink) Old 1-13-2020, 9:13 PM
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Welcome to the forum!
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post #4 of 14 (permalink) Old 1-13-2020, 10:41 PM
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post #5 of 14 (permalink) Old 1-13-2020, 11:12 PM Thread Starter
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Asketh, and thou shalt receiveth.

Thank you for this link!
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post #6 of 14 (permalink) Old 1-13-2020, 11:12 PM
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Welcome. It looks like you have some work ahead of you, but it’s worth it in the end.
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post #7 of 14 (permalink) Old 1-13-2020, 11:17 PM Thread Starter
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Welcome! We lost communication with the wiki during a software change last year. It's still accessible via Internet archives. There's an announcement at the top of most forum sections explaining how to access it.

I saw that. That's what I've been doing. However, the link to the Removing the California Emissions page wasn't archived.
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post #8 of 14 (permalink) Old 1-13-2020, 11:36 PM
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I saw that. That's what I've been doing. However, the link to the Removing the California Emissions page wasn't archived.
Ah, I know a couple of things didn't make it there. It's a shame that we lost the ability to access it from the forum, but we have plans to try to migrate that info on site. I'm hoping I see my way to get involved in that very soon.
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post #9 of 14 (permalink) Old 1-14-2020, 4:18 AM
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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 #10 of 14 (permalink) Unread 1-14-2020, 9:31 PM
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If I can't find the walkthrough of removing the CA emissions stuff, I should have the time tonight to write up a quick step by step tonight.

1990 EX500 - 145,000 miles as of November 25th, 2019
1993 Ducati 900SS - The real canyon carver
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post #11 of 14 (permalink) Unread Yesterday, 10:46 AM Thread Starter
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If I can't find the walkthrough of removing the CA emissions stuff, I should have the time tonight to write up a quick step by step tonight.
That would be great! I'd really appreciate that. I don't want to start pulling off random things.
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post #12 of 14 (permalink) Unread Yesterday, 12:22 PM
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Turns out I didn't have time last night so I'll do it this evening after work.

1990 EX500 - 145,000 miles as of November 25th, 2019
1993 Ducati 900SS - The real canyon carver
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post #13 of 14 (permalink) Unread Today, 2:06 AM
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Almost forgot about this. So, it's been a while since I've actually had an EX come through my garage which actually kept its CA emissions stuff for longer than about 10 minutes and I removed mine many years ago, so I'm not 100% positive on the exact hose routing, but I do have a bin chock full of removed emissions crap, so I can show you what needs to be removed and describe where to find it. What hoses need to come off will become apparent as they'll no longer go to anything.

Here's a picture of all the components which are emissions related which you will be removing. The big Y shaped thing of tubes at the top of the photo is the main component of the PAIR system which needs to come off, though it isn't part of the CA emissions stuff. The Toddlamp PAIR block off kit which Zerofret linked takes care of that. I didn't take a picture of the reed valve caps on the valve cover which also need to come off as a part of that, but I think you'll figure out what those are pretty quick.
The other 5 components are the meat and potatoes of the CA emissions stuff. What I don't have pictured is the several feet of vacuum tubing you'll be removing as well.



The biggest part, in the lower right, is the charcoal canister. That's the first thing you see when you pull the fuel tank. It sits on the bottom side of the upper fuel tank bracket.
The U shaped bracket above it in the picture is what holds it in place.
The smaller cylinder with vacuum ports coming out of it to the left of the charcoal canister is the separator, which is attached to the same bracket as the charcoal canister.
The plastic shroud to the left of the charcoal canister bracket sits around the separator.
The last part in the lower left is just a pair of metal tubes which route vacuum lines from the front bottom side of the fuel tank, around the frame and back to the emissions stuff. It is bolted to the frame behind the head tube (steer tube).

Take all that stuff and throw it in the trash. Then, take all the vacuum lines which attached to any of that stuff and throw it away as well. Actually, save the vacuum tubes, they make good spares for any of your future vacuum tube needs on any motorcycle or car/truck.

Once all that is off, you will only have one vacuum tube left and that goes from the left carb to the fuel petcock. The vacuum port will need to be capped off. If you buy the full Toodlamp PAIR block off kit (which I highly recommend), that comes with a good quality vacuum cap. Then remove the reed valve caps on the valve cover and install the block off plates. Then, install the cap into the front top edge of the airbox. You will have successfully removed the PAIR system.

On to finalizing the removal of the CA emissions stuff. There's a few things to tidy up. First, one of the two vacuum ports on the front bottom edge needs to be blocked off. The one with the red dot next to it is for positive pressure. The one with the blue dot is negative pressure (vacuum). Block off the one with the red dot. If you do not, the tank will occasionally develop a slight pressure and blow off, along with some gasoline, onto the top of your engine, or onto you at higher speeds. Don't worry about the fuel tank bleeding that pressure off, fuel consumption takes care of that while running and it'll bleed the pressure off slowly on its own at a stop. The blue dot tube needs to remain open to equalize the vacuum created by consuming fuel as there is no fuel pump. The vacuum will quickly overcome the force of gravity.
Next, one of the vacuum tubes off the charcoal canister goes to the front of the airbox on the lower right side. Remove the small rubber elbow in there and put a couple strips of whatever durable tape you have (duct tape, gaffer tape, electrical tape, etc.). I used black electrical tape as it is well camouflaged.

Functionally speaking, that does it for full emissions removal. Additionally, I like to chop off the charcoal canister bracket off the bottom of the fuel tank bracket. No point in keeping that big, clumsy chunk of metal in there anymore.

1990 EX500 - 145,000 miles as of November 25th, 2019
1993 Ducati 900SS - The real canyon carver
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post #14 of 14 (permalink) Unread Today, 2:47 PM Thread Starter
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Saabnut thank you for taking the time to explain all of that! I got the PAIR removal kit ordered and its on its way. Excited to get this bike up and running!
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