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Today is my best friends birthday, but he could not celebrate as he past away 11 years ago in a motorcycle accident. He lived in another state so I we never got to ride together. Today for his birthday I went on a 4 hour ride then finished it off with his favorite adult beverage. It was a good day!
 

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Today is my best friends birthday, but he could not celebrate as he past away 11 years ago in a motorcycle accident. He lived in another state so I we never got to ride together. Today for his birthday I went on a 4 hour ride then finished it off with his favorite adult beverage. It was a good day!
I can appreciate that.
 

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Rolled over 1000 miles on the digital odometer since I rebuilt the motorcycle. That’s just over 37000 miles on the engine now.
 

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Well last night I inspected a job my buddy and I did a week ago. Valve adjustment On the ex250 05 nocturne blue. I noticed that even though the coil was welded on it still had two bolts we forgot to put those two bowls on. One of the fairings was a missing bolt so at 5 a.m. I called my guy up and asked him about it we argued about it for an hour he had the one bolt in his pocket for the fairing I also remember that coolant O-ring going down past valve cover, was harder thanrock that I had to take out to pull out the valve cover so I think what we'll do is order the O-ring and then get back in there and put those bolts back and then double-check. We also changed out the clutch lever from when we accidentally dropped the bike. Both of us parking them on a facing downhill on the kickstand. he put his bike on the kickstand and I put my bike on the kickstand and then I was like hey come over because he couldn’t hear me “here look at this you shouldn't put your bike on the kickstand on the hill cuz Ii can fall!!!!” A second later we looked back at the 250 guess what was happening?
 

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The kit I got was a stage 7 which has a wide range of tuning. The instructions are easy to follow. The settings are not going to be the same for everyone, altitude, makes a big difference, also air pressure and humidity so you may have to play around with the air screw to smooth out the idle ( mines at 3 1/4 turns out) And the needle may need lifted or dropped a 1/2 clip to richen or lean out the fuel mixture. make sure the inlet manifolds are properly sealed to the engine. Make sure the slide vacuum rubbers are correctly placed in their allocated grooves, slide up freely and return smoothly. Use a little silicon grease around the edge of the vacuum it may help. Make sure your carbs and jets are all clean and your float levels are set to standard. Make sure your carbs are balanced, you can do this by eye watching the butterfly’s open and close and adjust the balance screw, but a better job with vac gauges. Make sure your compression is good, valve clearances are correct, you have fresh fuel.
The dynojet needles have a more aggressive taper, and also are adjustable so I wouldn’t try any modifications with stock needles. The slide hole is drilled out to 3.1mm and the softer springs makes it easier for the vacuum to lift the slide. There are a number of main jet sizes to then fine tune the full open fueling which will depend on your air filter and exhaust. The trouble shooting document that comes with the kit is really helpful for getting your head around what you need to adjust to iron out any running issues. And once you have the air box off it’s way easier to work on the carbs.
 

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Winter restoration of my new ex500. It's not as bad as it looks; the rest of the bike is in the kitchen. :smile2: My wife is thrilled.

I did the valve adjustment last night...maybe for the first time? 5,900 miles. Intake were fine - exhaust were all very tight, but they are now set to 0.008". Hopefully I'm saving it before serious damage was done. I torqued the valve-adjusting nuts to 18 ft/lbs, which didn't seem very tight, but hopefully that's all they need to stay put. It took a lot more to break them loose.

Below are before and after pics (before = 2003, after = 2020)
 

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I prefer the dining room myself. But that's just me.


Living room is OK for some things. Like trying to hook up my CB radio. :grin2:
 

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I prefer the dining room myself. But that's just me.
Living room is OK for some things. Like trying to hook up my CB radio. :grin2:

I moved the operation into the bathroom. The variable pressure Waterpik is a great parts cleaner - especially radiator fins. Plus of course there are toothbrushes everywhere. :wink2:
 

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I pondered adjusting my mixture screws yet again, last tank of gas only lasted me 97 miles which seems incredibly poor. I left them at 2.5 turns out previously and thinking of moving to 2.0 turns out or 1.5.

Long story short I did nothing :C
 

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I got the engine dropped out.

Installed air delete kit. for now.

Later tonight I got a clutch kit, valve adjustment, spark plugs. etc.. Whatever I can do before I plug this thing back in.

Stay healthy.
 

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I got the engine dropped out.

Installed air delete kit. for now.

Later tonight I got a clutch kit, valve adjustment, spark plugs. etc.. Whatever I can do before I plug this thing back in.

Stay healthy.
While it is possible to burn out the clutch on an EX, I'd say it's one of the most robust parts of these engines. I've yet to personally see a clutch go due to mileage and I know some of those who race here never needed to think about them. They do have notoriously weak springs which get weak with age and can imitate a bad clutch by allowing excessive slip due to lack of pressure. The common upgrade option used for the springs is Barnett spring kit 501-50-05055.

What happened to your clutch which made you decide to get a new clutch kit?
 

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The clutch on my bike can spin when I give it lots of gas, Does the Barnett spring kit make the clutch lever much harder to operate or is it barely noticeable? I previously fitted a conversion kit to my FJ1200 and while the clutch never slipped again it did make town riding a bad experience due to the clutch lever being difficult to keep pulled in.
 

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It is definitely noticeable, but I wouldn't not say it's unusually stiff. It's nothing compared to my stock 900SS, which is well known for an absurdly stiff lever.
 
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