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I've been working on this project bike for a few weeks now. Since I have a "daily rider" I'm not really in a hurry to get it wrapped up. I'll post updates and pictures as I make progress. Since it's my first bike project, I was a little slow out of the gates. The bike sat in my garage with little progress for a number for months, but now that I realize what a piece of crap I started with, I'm less worried about messing anything up.

From my original introduction post here: http://www.ex-500.com/index.php/topic,1928.0.html, you can get a good idea of the scope of the project.

I primed the frame in black today. I thought about spending more time cutting, grinding, and welding it before getting to the paint but I figured no matter how hard I work at it, it'll never be a show bike unless I dump an unreasonable amount of time and money into it. So, I'm going with the "good enough" approach and I figure that if it ever gets on the streets, it'll look fine from 10 feet away.


My to do list seems to be growing, not shrinking as I dive deeper into the project. I pulled the cam cover and discovered that one of my exhaust cam lobes has a nice chunk missing. Makes me think (1) why did this happen, (2) how bad does the rocker arm (or whatever it's called) look, (3) where is that missing chunk, (4) what exactly will I need to replace and how much will that cost?


Here's a pile of parts that I have to get working on.

The valuables include the R1 seat which needs to be modified a bit in order to fit the frame/tank, some bikemaster bars (can't beat the price), steering damper, grips, top triple clamp, a crazy headlight that might not make its way into this project, and the crown jewel, the all-in-one Acewell 2700-series gauge. I also have some extras including pistons, stator and cover, a decent set of clip-ons, an extra head, a somewhat nasty looking cam, a stock brake line, and some dog bones (is that what they're called?)

Here's a pic of the motor as it is at this moment.

I'm debating what to do with it. I might just give it a good cleaning and call it a day. Since I've never been into one before (only cars) I'm not sure what to expect. But, it's probably not too painful to pull the head and take a look at what's going on. I've contemplated asking FOG if he'll give it the royal treatment but I'm not sure if I have the motivation and funds to put it on a crate, ship it out, and go through with the whole thing.

Let me know what you think of the whole deal. I'd love to hear your comments, criticisms, suggestions, and whatnot.

Finally, here's a picture of some sand.
 

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You have quite a project ongoing there..

But it's off for a good start, the paint is awesome (I'm referring to the body too ;))

As for the engine, well it looks like it missed to TLC from the previous owner, if you want to cut it short, maybe you could get another engine ?

If you need extra funding, that pipe aside the engine could find a new owner rather quickly, carbon fiber is a must-have for many :)

Like the last pict too, where is that ?

Cheers
 

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i absolutely love the paintjob... quality job you did there... as for the engine... i would take your time and make sure you do it right. on my old harley m-65 rebuild project, i tried to cut it short and get some "specialist" to rebuild the classic engine... it came back looking great, except for the crate gettting damaged en route and damaging the engine... which would no longer turn over.

keep it at your house...
take it slow.
do it CORRECTLY.
if you need help--ask FOG or dad
grab the OEMs from bikebandit.com
and most importantly--- have fun... it is a flippin motorcycle
 

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quick question, in the first set of pictures on the original post, was the bike ratchet strapped to a car bumper? is that how you got it home? if so thats tits haha
 

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Discussion Starter #7
Yep, the bike was strapped to a car. But that was only for trips back and forth for track days. I didn't bring it home that way ;)

The picture above is from the Silver Lake sand dunes near Hart, MI.

I didn't make much progress this weekend because another bike showed up that needed some attention, plus I'm pulling the motor in my 99 Isuzu Trooper because it needs a rebuild. A friend brought a 1984 Kawasaki GPZ900 over to my garage and we spent a while stripping it down then getting it running again. It might make a fine sport cruiser if it ever goes back together.

As for the EX500 project, I found time to paint the frame with some high-temp engine enamel. Nothing fancy but it looks worlds better than when it arrived. Here's a picture:


I also had a chance to stop by the powder coater's and pick up my wheels and swingarm. They're nice but I'm sure the mismatched wheels will look a bit goofy:


I spent about 5 minutes trying to pull apart the front forks but the hex bolt in the bottom of each just don't want to come out. When I hit 'em with the impact, one just spins and the other won't budge. ??? I might outsource the rebuild of those to the stealership if my next attempt fails. Time permitting, I'll probably start running through the motor this week or next weekend. Does anyone have a good exhaust cam laying around that they can spare?
 

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Nice project you have going here. The powercoating is so purdy too, too bad the wheels don't match.
 

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I don't think the wheel differences will be noticed by 95% of the folks.
The rear wheel is generally hidden behind the brake on one side & chain/gear/guard on the other.

The front wheel is especially sharp & will be in full view from one side.

The whole project is looking SOoooo promising! Looking forward to updates as they come. 8)
 

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I'm trying to recall....I believe you have to use a wooden dowel or something similiar to hold the guts of the fork in place while trying to remove the hex you were talking about. I believe FOG has addressed this previously, he may have done so on one of the "other" 500 forums.
 
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