Ex-500.com - The home of the Kawasaki EX500 / Ninja 500R banner

1 - 19 of 19 Posts

·
Registered
Joined
·
37 Posts
Discussion Starter #1 (Edited)
So, another non-faired naked conversion type thing...

The bike is a '99 D6 with less than 18k miles on it (barely run in :D). I've owned it since August 2018, with this being my first bike that I've owned, and only the third that I've ever ridden.

A bit of backstory, as the bike was completely standard when I bought it, with possibly everything original from 1999 aside from tyres.


Then, annual MOT comes round, and I have a 2" hole in the exhaust crossover underneath, so in came a Delkevic 2-1 long can exhaust (would highly recommend, sounds lovely)


August 2019, I have a disagreement with a grass verge, resulting in the below. I still have the pieces, but it's not repairable unfortunately.


Fast forward to today, and the conversion has begun, generic 7" LED headlight and LED indicators on fork mounts have been added so far - thoughts on the headlight? I rather like it, but I know it's probably not to everyone's taste. It has a DRL ring that I need to wire in to the side light.



So, the future plans:

  • Bar end mirrors - can anyone recommend any? And how the hell do you get the bar end weights off?
  • Custom dash - I've cannibalised the stock dash, so standard speedo and temp gauge, with either no tach or a custom digital tach depending on how arsed I can be, in a self designed 3D-printed housing
  • Either custom side panels, or a new coolant expansion tank and some tidying
  • LED tail light conversion - I'm thinking of trying to use an ER6 or Ninja 650 one, as I quite like the shape of them
  • Some sort of tail tidy
The aim is a kind of cyberpunk style streetfighter thing, sort of like the Honda 'Neo Sports' range, although I'm always open to suggestions :grin2:
 

·
Registered
Joined
·
37 Posts
Discussion Starter #3
The indicators i found had integrated ballast resistors, i did need a new relay though. The headlight seems to be absolutely fine, it's designed to fit anything with a 7" light i think, the pictures had Jeep Wranglers, classic bikes, old Land Rovers.
 

·
Registered
Joined
·
62 Posts
I see, I'll probably switch to one of those headlights eventually. Big fan of that ring around the light.

Also debating on what I want to do for my tach. I've heard that peak power comes around at almost 10k RPM, and with the 11k RPM redline, I don't want to push it that far without one. Want to do a traditional gauge pod like my speedo, but I'd have to deal with the wasted spark system and figure out a way to divide the frequency of the engine pulse.

edit: the bar ends should just screw off, I think mine were loctited though so you'll either need some heat or a lot of force. The EX's bars are weird, I don't think they accept most bar-end mirrors without some kind of modification. I have some, but I have a set of bar end weights with a tapered end to attach them to.
 

·
Registered
Joined
·
37 Posts
Discussion Starter #5 (Edited)
I've seen a few people have made various designs using an Arduino, I was eventually thinking of having it running around the outside of the temp gauge, than I can have an even twin pod set up rather than a big pod and a small pod. I'll have to see how it looks, at the moment I feel like it might look like the headlight from a BMW GS :p

On the power band note, I used to have a Civic Type R that was similar - peak power was 7800 rpm, redline was 8000 rpm, rev limiter was 8200. Such a stupid, fun car...

edit: with the bars, i read somewhere that they were standard 7/8" bars? I was going to trim the end weights down and fit the mirrors between the grips and the weights. Has anyone else done similar?
 

·
Registered
Joined
·
742 Posts
Saw the title of this thread and was thinking evil thoughts!!! >:) >:) >:)


As for your bar ends...pull, hard!
 

·
Registered
Joined
·
248 Posts
Cool stuff!

If helpful, here's the wiring diagram for a frequency divider, which will let you use an aftermarket tach, and make it read correctly with the wasted spark system. I didn't make the circuit board pictured myself, but it is the one that's in my bike, and it works perfectly.

Check out my thread (link in signature) for more on that.
 

Attachments

·
Registered
Joined
·
62 Posts
Cool stuff!

If helpful, here's the wiring diagram for a frequency divider, which will let you use an aftermarket tach, and make it read correctly with the wasted spark system. I didn't make the circuit board pictured myself, but it is the one that's in my bike, and it works perfectly.

Check out my thread (link in signature) for more on that.
Was that wiring diagram in your thread lol? Didn't see it last i looked through, gonna be real helpful when I decide to pick up the new tach.
 

·
Registered
Joined
·
37 Posts
Discussion Starter #10
So, version 1 of the dashboard is well underway 😁 no tach or temp, but that's not such a problem this time of year in the UK...

IMG_20200328_082932.jpg IMG_20200328_083154.jpg IMG_20200328_085239.jpg IMG_20200328_095220.jpg IMG_20200328_095237.jpg

Just need to cut some perspex, then make the top cover, tidy up the wiring and figure out how to mount the thing.

On a different note, has anyone ever seen a 500 with a high mount exhaust under the tail, sort of like an '08 Ninja or Triumph Sprint 1050?
 

·
Registered
Joined
·
37 Posts
Discussion Starter #12
So, a quick progress update (or rather lack-of-progress). The PCB in the stock tach apparently doesn't work how I wanted, the voltage supplying the magnet that drives the needle apparently drops as the revs rise, so a new plan is needed there.

Also, the screws in my bar ends are well and truly stuck, so got some extractors in the post.

At least I'm finally getting time to sort this stuff, what with lockdown and all :rolleyes:
 

·
Registered
Joined
·
37 Posts
Discussion Starter #13
And now some actual progress...
51276


I finally have mirrors again :D

51277


Dash is coming together, just need to print some mounts and cut some clear acrylic, and I'm back on the road hopefully.

Might just be in time for lockdown ending...

Out if interest, what do people think of Moto bar conversions?
 

·
Registered
Joined
·
37 Posts
Discussion Starter #14
And we're back on the road :D

51382

51383

51384


Shame I could only go to the supermarket, but it's something.

So, short term next steps:
  • Ride her, a lot!
  • Figure out the coolant expansion tank
  • Reprint the dash in the proper material
 

·
Registered
Joined
·
37 Posts
Discussion Starter #15
So, a virtual update this time, designs for a new expansion tank:
51532

I've got a friend who's a dab-hand with a TIG welder, so some 2mm aluminium sheet and a few weld on off-the-shelf bits and we should be good to go hopefully.

Does anyone happen to know what the stock min and max coolant levels are? I roughly measured at about 250ml and 420ml in the tank respectively, so a 520ml tank should work?

Also, shout out to @kiwigpz for the inspiration, even if this in the stock location for now.
 

·
Registered
Joined
·
2 Posts
And now some actual progress...
View attachment 51276

I finally have mirrors again :D

View attachment 51277

Dash is coming together, just need to print some mounts and cut some clear acrylic, and I'm back on the road hopefully.

Might just be in time for lockdown ending...

Out if interest, what do people think of Moto bar conversions?
Looks good, do these screw in to the threaded piece on the end of the bar? where did you get them? Thanks
 

·
Registered
Joined
·
37 Posts
Discussion Starter #17
Looks good, do these screw in to the threaded piece on the end of the bar? where did you get them? Thanks
Yeah, I took the bar end weights off to do it but you could probably put them on the end of the bar weights.

They just came from eBay, nothing fancy, but the work and I like the look of them.
 

·
Registered
Joined
·
37 Posts
Discussion Starter #19
I used a screw extractor in the end, one of those double ended ones for removing stripped screws. Pretty much the same as these:


I know a few people have had success with heating them but I don't have a blowtorch or anything like that.
 
1 - 19 of 19 Posts
Top