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"And it just seems strange that the bike dies when I take the choke off with the pair hose in the airbox. But when I remove the hose it runs fine with the choke off."
Strange indeed! Runs on choke makes it sound too lean; runs good with extra intake source makes it sound too rich.
Anything obstructing the air cleaner element or the air horn under the right side of airbox?
 

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Tanker Clown
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And it just seems strange that the bike dies when I take the choke off with the pair hose in the airbox. But when I remove the hose it runs fine with the choke off.
Sounds like the carbs are set on the rich side. Removing the PAIR hose is allowing more air to enter the airbox. If that makes it run better then too much fuel is being delivered.

Best to never use small independent bits to scour rust off the inside of a tank. A 6”-8” length of bicycle chain is better. One piece to account for means no chance of a stray nut or bolt getting caught in a seam or baffle.

A lost nut or bolt could come back to haunt later on down the road. And not in a way you might imagine.
 
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Discussion Starter · #23 ·
Not that I see no. The snorkle on the right hand box is clear and the filter is brand new K&N.
I might do the pair delete anyways for the sake of clutter. And I'm considering the Fog Mod to maybe address the throttle lag.
 

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Discussion Starter · #24 ·
Sounds like the carbs are set on the rich side. Removing the PAIR hose is allowing more air to enter the airbox. If that makes it run better then too much fuel is being delivered.

Best to never use small independent bits to scour rust off the inside of a tank. A 6”-8” length of bicycle chain is better. One piece to account for means no chance of a stray nut or bolt getting caught in a seam or baffle.

A lost nut or bolt could come back to haunt later on down the road. And not in a way you might imagine.
An old chain would be a good idea. My gxsr tank is probably actually in need of an R/R when I redo it. I'll keep this in mind.
 

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Discussion Starter · #25 ·
Ok gentleman I'm having a small last issue. Buttoning everything back together. Putting the caliper springs back in, but for the life of me I can't figure out how this rear caliper spring orients.
Can't find any pictures and I've yet to be able to find a manual to buy.
Anyone got any picks of the caliper springs installed or know where I can find the info?
 

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2001 EX500R
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Discussion Starter · #31 ·
She's alive!!! Runs, rides, stops. Lags around 4k rpm.
Stalled on me at a stop twice. I have it idling around 1500 though cause any lower and she dies.
Could be because I have the pair hose unplugged but it dies with the choke off when it's plugged in.
Got Mr. Lampones kit on the way to get rid of it. So I'll update with the system off.

Just wanted to say thanks for all the tips from everyone in the discussion. Really appreciate the help.
 

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Discussion Starter · #32 ·
@ducatiman Good day sir. I don't know if you have a quick link or if I can PM you. But I'm looking for a Carb rebuild kit for my 01.I've been scouring different carb issue posts but couldn't find an actual link or price. I live in Canada so sending my carbs your way isn't very doable for my with the season upon us. So I'll be looking to replace the oring internals and stuff while I have my jets and bits being ultrasonic cleaned. Got anything still kicking around for sale?
 

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Tanker Clown
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Pretty sure the link is in his sig at the bottom of any of his posts
 

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no they are not supposed to be there looks like some half hearted attempt at getting more air into the box.
plug them up and start again with a 1in hole on the left case only.
 
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Discussion Starter · #37 ·
Ok. Holes have been plugged with Ultrablack RTV and a new 1" hole has been inserted into the back of the left cover.

I have also installed Lampone's pair removal kit.
54423


Sexy and clean.

My carbs ended up having a tear in a diaphragm so the carb bodies are currently being ultrasonic cleaned while I await my all balls rebuild kit.

I have ghettofabbed the diaphragm tear with some Permatex Ultra Black.
I've also ordered a chinese made diaphragm replacement for $8. I will try one then try the other if I have too then worst case fork out $180 for an Oem piston replacement.

Also swapped in iridium plugs for good luck.

And since I had the rust issues with the tank I added in the OEM Alternate # fuel filter in the lower rail tube.
54424
 

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Discussion Starter · #38 ·
Awwwwwe helll yeah.
The carbs came back clean AF.
Gave me an itch to paint them(Don't ask).

Kinda cute, no?
54458
54459
54460
54461
54462


And then voila!!!

54463


Started up with some time to let the fuel run through and had the idle down to around 1300 with no issues.
Seems like the diaphragm rtv is holding. Could notice a difference with the plungers as soon as I reassembled them.

Took me almost all night to get the carbs back together so I'm gonna tune the jets to the Fog Mod tomorrow.

WOOOOOO. Sweet sweet victory.
 

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Discussion Starter · #39 ·
Ok. The rundown.
Bike. $600
Brakes. $17.65
Grips. $13.68
Tires. $169.00
Carb Kit $75.91
Boots $8.06
Lampone Pair Removal $52.28
Fuel Filter OEM $9.00
Oil/Filter/Battery $178.39
Plug $4.05
Iridium Plugs $21.68

For a grand total of $1149.70
All prices in CAD and include shipping costs.

I was aiming for $1000 or less but the pair removal, carb kit and iridum plugs, put me that extra over. But I'm ok with that. Just the sound of her turning over and idling at 12-1300 last night brough joy to my weary back.
 

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Discussion Starter · #40 ·
WE'RE BACK!!!

So last summer I rode the girl as much as I could.
Since I couldn't get my hands on the fairings I needed for less than $250 I opted to stick to my original plan of swapping the headlight out. After which I decided to swap the gauge because it was too big and bulky.
Vehicle Automotive lighting Wheel Plant Automotive tire


Blue Automotive tire Motor vehicle Fender Gas

Plant Tire Vehicle Motor vehicle Automotive tire


The new gauge lacked some indicator lights so I wired some in separately. Had to fashion some makeshift brackets out of old steel I had lying around. They'll be swapped for prettier versions next year.

Light Tableware Kitchen utensil Gas Nail

Cameras & optics Gadget Audio equipment Input device Camera lens


The brackets were painted black to sit nicer with the bars.

I also wired in sequential LED turn signals since everything attached to the front cage was gone. But that also meant resistors to keep the flow right. I mounted them to a bracket then mounted that to the empty front bracket from the old cage.


Tire Wheel Automotive lighting Motor vehicle Automotive tire


Then I wired in the indicators and loomed everything up and here we are!!

Wheel Tire Fuel tank Automotive lighting Automotive tire

Tire Wheel Land vehicle Fuel tank Vehicle

Motor vehicle Electrical wiring Gas Auto part Cable



I have one more project for it and that's to swap out the overflow for this Crystal Skull bottle.
I just got a 3d printer so I'll be desiging a bottom bracket for it to mount where the old cage mounted at the side. And a top strap to keep it snug and steady.


Stay tuned for the finish!!!
 

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