[FlipFlop]

I have posted a few Pictures in the Intro part of the forum but really did not want to post too much there as it is for introduction.

I will update as I go through with this build. I will also try to describe what I did as i go rather than just a mass of pictures.

The day I brought it "Back Home" to Indiana from Fairborn Ohio about a two hour drive away it turned out it came from this area. It has a salvage title however it is in good shape and the cluster was apparently and happily changed to this higher mileage one. I really don't know what the mileage is but from what I am seeing the motor is likely to have low miles or "lightly" used miles as the motor is very very clean and the carbs still have the factory plugs and it starts and runs runs decent although out of sync..

Day we bought it Saturday December 12 2020

 

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Got it off the trailer and on the Lift on Monday the 14th after taking it up to the BMV so they can get a very cold look at the VIN since it came out of state.

Removed all the AirTech and what ever the lower was and the rear panels to get a good look at the bones of the bike.

Removed the Pair system with some temp plugging and the beat up exhaust (although the header was mainly what was beat up)

Removed that fender eliminator kit.

Tank is very clean even inside, In my opinion another sign of the bike at the least being kept indoors not out in the elements.

Front tire is from 2008

 

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I was very pleased that the wiring was not chopped up since I saw some weird LED stripes on the bike into the fuse box and the fender eliminator had wires ran up to the front signals I just knew the wiring was chopped but it was minimal just the former owner did not know there was an actual plug for the front lighting.

Holes in the frame where they put wood screws through the fiberglass to the frame to hold them up on both the upper and lower fiberglass bits.

Ordered Fog bones and rear set from Fog this stock set up does not work for me just too close for my big feet.

Removed the radiator since all the hoses could tell there was seepage from all the ends of the hoses.

Clutch cable is going to be a goner, fraying so, on order that part is.

Notice the universal side stand, everything is lowered and very low.

 

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Saturday 12-19-2020

Received my Fog bits, even my wife could see the quality in his work. They are sturdier than the bike themselves, could not wait to install them love them.

SV650 Shock installed with the Fogbones putting the bike at about 2 inches taller in the rear and tore into the forks, not really rebuilding them as much as resealing them and replacing the fork oil and internally cleaning them up. I also added 1ounce of Motorkote to each fork (11 ounces of 15weight + 1 ounce of Motorkote)

Received the stock rear fender for 5.00 shipped cleaned it up and installed it with the stalks shorted down and installed LED 1156 Amber bulbs.

Got the paint gun out and shot some paint it is 3 part Acrylic enamel. Just a random Red I choose on their color swatches at NAPA.

 

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Brake Lines that were intended for my CBR1100XX to de-link the brakes and never did. Two of the lines were perfect for where I slide the fork to stand the front end up and to replace front and rear with new none rubber brake lines by HEL, nice stuff IMO.

Received my 17 tooth front sprocket and my spare wheels that I will be cleaning up in black and polished lips.

My favorite part... shiny stuff... Since finding stock stuff was not really my true intention although was a stock"ish" look was desired. I did find this jewel on fleabay for 400.00 free shipping the Delkevic Full 2-2 Exhaust exhaust in all Stainless. Only catch I needed to buy the bits to attach it to the motor, since the Muzzy system was on that system exclusively. So I bought a bulk bolt from someone stripping a poor Ninja at a scrap yard.

 

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Tue 12-22-2020

I had also ordered a new Nickle X-Ring 520 chain and a new rear 42 sprocket they showed up and got them installed.

Also ordered battery electrolyte topped the battery off, and installed the battery tender plug and the K&N filter and got that whole are done up with a similar to the Fog air box mod, although it is actually more the Aph air box mod since it is what I done to my 1988 one before I ever joined or knew anything about ex-500.com much less Fog, but here you say Fog air box box mod you know what it does.

Got the exhaust on with the arrival of the bulk bolts I bought very pleased with how things are coming.

 

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Friday Christmas 12-25-2020

Got my rear spools installed, w/ thread lock and set up with the modified rear stand. The factory rear stand I think they wanted the center stand off and the exhaust would have been in the way so they cut the tabs off rather than to remove the exhaust.

Front Fender installed and got all the angles sorted to make sure it was not twisted and and to be true straight.

Bleed out the brakes rear good so that all the old fluid was flushed out.

Removed the paint roughly off the front wheel lips.

Extended and tested the adjustable side stand. At its maximum settings it just "works"

Also installed the additional spacer that Fog provided for the shifter and like it much better.

 

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Saturday 12-26-2020

Could not sleep got up early dis-mounted the rear tire and man was that a bugger to get that hard sumbuck off. It was from the end of 2001 according to the date stamp. Cleaned the wheel where I wanted it black and made it Gloss universal duplicolor black.

 

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And the back wheel with the paint removed from the lips and smoothed (not polished yet) and then cleaned and painted.

 

[yorkie]

WOW. you don't mess about do you. LOL. it took me two months to get so much done. 3 months before I had a rolling starterble bike. mind you it was a complete strip down and rebuild with new parts. well done.

PS, in the picture of the removed suspension coupler and dogbones what bike is that off it not a stock EX500 one wrong shape.

 

[FlipFlop]

PS, in the picture of the removed suspension coupler and dogbones what bike is that off it not a stock EX500 one wrong shape.

That would be to a 2003 Suzuki SV650 thought about trying to raise the rear of the bike using that and a SV650 shock, it does work but a little too well and the chain hits the swing arm then too.

 

[yorkie]

ok thanks. that end connector does look a bit aggressive for an EX.

 

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Installed the new clutch cable.

Replaced

Also installed 194 bulbs in the instrument cluster with LED Simdevanma 194 that I bought on Amazon.

The LED's

The Incandescent

 

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Got my Tank Lock Givi Stuff and installed it on the tank to have a look at it.

It is the 15L GIVI XS307 XStream Tank lock - Black I had to buy the lock metal lock ring separate, just found a cheap one for a different Kawasaki and drilled new holes for 2 of the bolts. I have about $150.00 usd from eBay in the whole thing with shipping, but it will keep my tank bag off my new paint. I butchered the innards of this tank bag because it came with this liner thing that had a drawstring on it that felt like it was made out of tent material, I guess to help keep things dry maybe. I did not like it and removed and just have the plain clean innards to set whatever. Anywho this was my Happy New Year project this AM.

 

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Up next carb rebuilding, something is causing them to dump fuel into the carbs... Time to tear em down and clean them up. They still had the factory plugs on the air screws, and took them off and the air adjustment was all over the place. Running rich and inconsistent. Yuck.

 

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Got the carbs done forgot to take pictures as I went, but did a few. Benched them, and wet tested them first then I manometered them in on the bike. I changed the fuel line and used the fuel line you can buy for lawnmowers 3/8 clear fit beautifully and added a fuel filter from the same place you buy the hose and mounted it right between the carbs and tuned it with it in place. Decided to add some vacuum caps to cover the adjuster screws. So far very happy.

I changed the spark plugs they were very ugly and wet from the bad running carbs, Never used those type of plugs only used NGK D9's and D8's. For today the bike got D9's. In the process of all this before I did anything with the bike running I changed changed the oil with Rotella and a shiny new filter ProSelect from NAPA #21356. Was a good day and happy with the progress made today...

Now where is my fairings so I can get them painted...

 

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[bpe]

Now I want some vac caps on my pilot screws. 😃

 

[Davenay67]

I really like your remote fuel source. It reminds me of the fuel tank from one of my Dad's old lawnmowers. He was old-fashioned, and always used the type with the cylindrical blades in the same pattern as snow blower augers.

I've been using funnels and it is definitely not the best. I really need to look into to a dedicated tank.

 

[haybaler]

I've been using funnels and it is definitely not the best. I really need to look into to a dedicated tank.

I look around Craigslist or at the salvage yard, for an older tank, metal or plastic from a smaller bike;
allows access to the synch adjusters, and you can test ride, warm up without putting the real gas tank back on.

Like this one: