Carb Cleaning....almost - Page 2 - Ex-500.com - The home of the Kawasaki EX500 / Ninja 500R
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post #26 of 43 (permalink) Old 7-31-2019, 3:13 PM Thread Starter
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It's a little dirty
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post #27 of 43 (permalink) Old 7-31-2019, 3:37 PM
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It's a little dirty
What is that debris in the spark plug well? Rust particles?

I hope a new set of spark plugs is on your shopping list....

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2001 Honda VFR 800
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post #28 of 43 (permalink) Old 7-31-2019, 11:23 PM Thread Starter
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Yeah there was a bit of rust in there and some other corrosion.
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post #29 of 43 (permalink) Old 8-6-2019, 1:03 AM Thread Starter
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Right side plug
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post #30 of 43 (permalink) Old 8-6-2019, 1:04 AM Thread Starter
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Left side
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post #31 of 43 (permalink) Old 8-6-2019, 1:07 AM Thread Starter
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I just finished taking the cover off tonight and I'm going to try and finish up the valve clearance check/adjustment tomorrow and hopefully get some gaskets in to replace some of the old ones .
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post #32 of 43 (permalink) Old 8-6-2019, 9:03 AM
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Left side
Yikes. This plug is just gone. No electrode left at all.

Safe to assume the bike should run much better with some new plugs. Definitely replace them before attempting any fine tuning of the A/F screws on the carbs.

2007 Kawasaki EX-500 Ninja
2001 Honda VFR 800
2000 Kawasaki KDX 200
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post #33 of 43 (permalink) Old 8-10-2019, 12:55 PM Thread Starter
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Finished the carbs, screws were set to .5 and .25 factory, Valves were completely closed and are now set to .006/.008, spark plugs/wires trimmed and cleaned up, all new gaskets, lubricated all cable lines, cleaned the air filter , drained and replaced all fluids and well I dropped my battery terminal mounts somewhere and have to pick up new ones today, once I get that I should be able to start it up.
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post #34 of 43 (permalink) Old 8-10-2019, 12:59 PM Thread Starter
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Brakes and chain were good as well, I just need to get a broken bolt out of my kick stand mount so I can put it back on and do some repainting and it should be done.
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post #35 of 43 (permalink) Old 8-10-2019, 1:00 PM Thread Starter
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@bpe your valve clearance and spark plug guides were a huge help, thank you.
@ducatiman thanks for the kit it worked out great and was alot easier to put back together.
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post #36 of 43 (permalink) Old 8-10-2019, 1:15 PM
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Quote:
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Finished the carbs, screws were set to .5 and .25 factory, Valves were completely closed and are now set to .006/.008, spark plugs/wires trimmed and cleaned up, all new gaskets, lubricated all cable lines, cleaned the air filter , drained and replaced all fluids and well I dropped my battery terminal mounts somewhere and have to pick up new ones today, once I get that I should be able to start it up.
Wow, another one. I'll bet you're glad you spent the time on it. This "tight valve syndrome" is becoming quite common on the forum with the current crop of new owners. Valid testimony......

EX owners.....do NOT blow off the need for this vital service procedure!

An aside and a tip.....I remove the hardware on my old batteries going to recycling. Both bolt and square nuts...got a drawer full. Dropping common, good to have emergency junk around.

“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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Last edited by ducatiman; 8-10-2019 at 1:17 PM.
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post #37 of 43 (permalink) Old 8-10-2019, 6:08 PM
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@bpe your valve clearance and spark plug guides were a huge help, thank you.
@ducatiman thanks for the kit it worked out great and was alot easier to put back together.
I'm glad to hear those guides helped you out.
The valve adjustment guide was done on the other forum more or less as a first draft. I was wanting to improve upon it before bringing it over here. Not that the information isn't valid, but to just present it better, and maybe more in depth. I know now based on another thread earlier, it at the very least will need an oil pipe O-ring pic.

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 #38 of 43 (permalink) Old 8-10-2019, 11:32 PM Thread Starter
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Unfortunately bad news, I started everything up and rode it around today just checking everything I did maybe 30 miles all together on city roads. Everything was going fine until I heard a pinging sound and then it started smoking, I pushed it back to my garage and gave it a look over and it seems one of my valve cover bolts blew off. I honestly have no clue to what would cause that, everything else looks fine on it just in that one spot the bolt is completely gone.
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post #39 of 43 (permalink) Old 8-11-2019, 12:24 AM
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Metal fatigue from previous installations. Finally went over limit and cracked. One tell-tale indicator of fatigue-limit failure is lack of deformation. You can put broken pieces back together and it'll look brand new. In contrast to overcoming yield or strength-limits which will show bending and stretching.

What most likely happened in this instance was valve-cover had leak. Rather than replacing valve-cover gasket, lazy PO just tightened bolts more (not realizing bolt bottoms to prevent over-compressing gasket). When that didn't stop leak, they tightened it even more to no avail. Went well over torque-spec for that bolt, but not quite enough to get into plastic region or beyond. Repeatedly overtightening results in microscopic cracks that spread over time. Eventually tiny bit of stress like hitting bump finally connects all the cracks and bolt breaks.

I'd like to track down all PO of all bikes and give them sound beating!
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post #40 of 43 (permalink) Old 8-11-2019, 2:05 AM Thread Starter
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Yeah, real sad about it lol... It was sounding so good.
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post #41 of 43 (permalink) Old 8-11-2019, 6:10 AM
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These bolts get snapped off all the time. Usually when torqueing (over torqueing) them down. The valve cover gasket should last over 50,000 miles, being able to remove the cover at least 5 or 6 times before replacing.

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 #42 of 43 (permalink) Old 8-11-2019, 8:12 AM
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A session with an EZE out in your future, get a new bolt on order ASAP. Those VC bolts do not need to be super tight, simply snug.

I frequently get this with carbs...gorilla torque on float bowl screws, PO's trying to eliminate a leak not by correctly replacing the bowl oring but compensating by grossly overtightening the mount screws. Inevitably...the orings are found flattened beyond all comprehension.
Different location, but a similar mindset and equally poor mechanical execution.

“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 #43 of 43 (permalink) Old 8-11-2019, 11:57 AM Thread Starter
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Yeah I only made it snug nothing crazy. I think my Dad probably mentioned making it snug more times than this entire forum through random text messages. I ordered all new bolts, hopefully they'll get here soon.

Last edited by Selttus; 8-11-2019 at 11:59 AM.
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