issues common to EX500 post up known issues(all years) - Ex-500.com - The home of the Kawasaki EX500 / Ninja 500R
 
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post #1 of 14 (permalink) Old 8-7-2008, 12:06 PM Thread Starter
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issues common to EX500 post up known issues(all years)

This is intended to be a simple compilation of known issues specific to the EX500's. please try to keep all side chatter to other threads so new members and anyone wanting an idea of specific issues to our bikes are can easily find what they need.

Moderators, could we make this a sticky for ease of finding it?

Here's what I'm aware of. FOG will surely be able to provide extensive input on what needs improvement or may be an issue mechanically.

first gens:
flywheel magnet issue where magnets will sometimes become dislodged and require replacement of the flywheel. 2nd gen mod completely resolves this.

transmission isnt as durable(also resolved in 2nd gen bikes and 2nd gen transmission is direct bolt in fix for it)

wheels are 16" and tire options are fairly limited compared to 2nd gen 17" wheels. minor issue, but worth mentioning.

2nd gen 500's:
nothing really comes to mind besides soft suspension.

ALL years:
suspension in front and rear is soft and needs significant improvement for most riders weight.
valvetrain not designed for such high RPM engine, needs shim under bucket setup.
engine doesnt have rev limiter of any kind. (just a fair warning)

for best results, mix with beer and motors. <br /><br />2 86 Ninja 1000R's
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post #2 of 14 (permalink) Old 8-7-2008, 12:07 PM
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Re: issues common to EX500 post up known issues(all years)

lets not forget those cables that are coming loose on people
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post #3 of 14 (permalink) Old 8-7-2008, 12:55 PM
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Re: issues common to EX500 post up known issues(all years)

heres one. if you have an owners manual read, and then reread it again. if don't have one, find some who does, and steal it, i mean borrow it.

teach\'em right, and they will always go the right way.
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post #4 of 14 (permalink) Old 8-7-2008, 12:56 PM
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Re: issues common to EX500 post up known issues(all years)

Quote:
Originally Posted by lild
heres one. if you have an owners manual read, and then reread it again. if don't have one, find some who does, and steal it, i mean borrow it.
+1000000000000000000000000

some other prevalent issues that should be mentioned/addressed in sticky

plugged tank vent-itis
CC filling with fuel
petcock malfunctions
carb float system malfunctions

“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 #5 of 14 (permalink) Old 8-7-2008, 1:07 PM
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Re: issues common to EX500 post up known issues(all years)

yeah, general "lack of fuel filter" problems.

+1 to the speedo cable vibrating loose.

another thing I have seen on almost every 500 i've ever looked at are the scratches on the side fairings. When you take off the gas tank, it's almost impossible to avoid scratching your paint unless you have the side fairings masked off. not a 'problem' but definitely a design flaw.

I would call the stock signals a "problem." Popping out the metal bracket part of the stock signal should be a 'must-do' mod IMO.

do craptacular mirrors count as a mechanical problem?

'97 EX500 (SOLD March, 2011)<br />'93 CBR F2 (track - sold)<br />'03 600RR (track - sold)<br />'00 Honda XR100 (race mule)&nbsp; OMRL #524, stock XR100 and Formula 3!<br />'00 Suzuki GSX 750F (ugly street mule)
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post #6 of 14 (permalink) Old 8-7-2008, 2:45 PM
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Re: issues common to EX500 post up known issues(all years)

Quote:
Originally Posted by ducatiman
Quote:
Originally Posted by lild
heres one. if you have an owners manual read, and then reread it again. if don't have one, find some who does, and steal it, i mean borrow it.
+1000000000000000000000000

some other prevalent issues that should be mentioned/addressed in sticky

plugged tank vent-itis
CC filling with fuel
petcock malfunctions
carb float system malfunctions
Hey all,
I'm working on putting together a wiki page for this thread. I'm trying to list each item as,

Symptom -- ..................
Problem -- .................
Solution -- ................

But I'm having some trouble describing the symptoms of some of these issues... what are the symptoms of petcock malfunction? What are the symptoms of carb float malfunctions? etc....

You can view the article (work in progress) here --
https://www.ex-500.com/wiki/index.php/Common_Problems
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post #7 of 14 (permalink) Old 8-7-2008, 2:55 PM
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Re: issues common to EX500 post up known issues(all years)

Quote:
Originally Posted by ShadesOfGray

Quote:
Originally Posted by ducatiman
Quote:
Originally Posted by lild
heres one. if you have an owners manual read, and then reread it again. if don't have one, find some who does, and steal it, i mean borrow it.
+1000000000000000000000000

some other prevalent issues that should be mentioned/addressed in sticky

plugged tank vent-itis
CC filling with fuel
petcock malfunctions
carb float system malfunctions
Hey all,
I'm working on putting together a wiki page for this thread. I'm trying to list each item as,

Symptom -- ..................
Problem -- .................
Solution -- ................

But I'm having some trouble describing the symptoms of some of these issues... what are the symptoms of petcock malfunction? What are the symptoms of carb float malfunctions? etc....

You can view the article (work in progress) here --
https://www.ex-500.com/wiki/index.php/Common_Problems

both can, or may not have common symptoms. however, they do work in conjunction with one another as the "fuel delivery system".

float malfunctions (sticking needle & seat due to dirt, contaminants or maladjustment or an actual leaking float cell) CAN cause starting problems, flooding, stalling, leaking at the carbs.
in combination with petcock NOT shutting off, leaking float can fill CC with liquid gold.
if petcock CAN't flow....well, obvious, no run, no start.

the petcock SHOULD flow when vacuum applied to the diaphragm side
it should NOT flow when vacuum discontinued

“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

Custom Carb Service

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post #8 of 14 (permalink) Old 8-7-2008, 4:12 PM
 
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Re: issues common to EX500 post up known issues(all years)

The metal coat-hanger looking bracket holding the cables near the horn is prone to breakage.
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post #9 of 14 (permalink) Old 8-7-2008, 4:29 PM
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Re: issues common to EX500 post up known issues(all years)

Quote:
Originally Posted by ducatiman
both can, or may not have common symptoms. however, they do work in conjunction with one another as the "fuel delivery system".

float malfunctions (sticking needle & seat due to dirt, contaminants or maladjustment or an actual leaking float cell) CAN cause starting problems, flooding, stalling, leaking at the carbs.
in combination with petcock NOT shutting off, leaking float can fill CC with liquid gold.
just something to add... this may cause you to smell gas in your oil.
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post #10 of 14 (permalink) Old 8-7-2008, 5:03 PM
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Re: issues common to EX500 post up known issues(all years)

If i have to do any more cleaning up in this thread, it will be locked.

I am also moving this to the Wiki area.


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post #11 of 14 (permalink) Old 8-7-2008, 6:30 PM
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Re: issues common to EX500 post up known issues(all years)

just wondering if maybe you could stickie the thread title in the forum, and have the link there, so when a new guy/gal comes they will know it exist?

teach\'em right, and they will always go the right way.
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post #12 of 14 (permalink) Old 8-7-2008, 7:42 PM
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Re: issues common to EX500 post up known issues(all years)

sticky set.


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post #13 of 14 (permalink) Old 8-7-2008, 8:29 PM
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Re: issues common to EX500 post up known issues(all years)

Quote:
Originally Posted by Chenzo
The metal coat-hanger looking bracket holding the cables near the horn is prone to breakage.
so THAT'S what that thing hanging around my speedo cable and brake line was..

i thought it was supposed to be there until ducatiman kindly informed me that it broke off of somewhere. i guess i never bothered to look at the ends and see that it was visibly broken off.

anyhoo, i threw it out and it doesn't really do anything anyway..

My First Bike --&gt; 2002 Ninja 500 aka Madelyn *sold*<br />My Second Bike --&gt; 2005 ZZR600 aka Erisa *sold*<br />My Third Bike --&gt; 2007 ZX6R aka Track Bike only
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post #14 of 14 (permalink) Old 8-8-2008, 2:06 AM Thread Starter
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Re: issues common to EX500 post up known issues(all years)

I guess earlier I forgot to add, re aiming the headlight to correctly light the roadway in front of you is a bit of an issue. simple adjustment makes a HUGE difference in the stock light's ability to do its job effectively.

for best results, mix with beer and motors. <br /><br />2 86 Ninja 1000R's
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