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Discussion Starter #1 (Edited)
ZeroFret's '05 Cafe Project Log

Figured since I hadn't started a new thread all about my bike yet, I might as well get one going.

Long story short, the bike was given to me for free by a friend of my girlfriend's. It came with the undated title, but it has been sitting outside under a cover for at least six years. It took a while to get it home, and then longer still for me to find time to work on it. Since then I have followed some advice found here to go through a checklist of things to do before attempting to start it. Where I'm at right now is that I've verified that the cylinders are not stuck, and that all of the electronics work. Next step is to purchase all new fluids, spark plugs, and oil filter for it. I'll have to pull the carbs and clean/rebuild them as well.

The bike is not a show piece, and I found that the front fairing, and one of the front turn signals are damaged. I keep going back and forth over whether I will do any mods to it or not. I'm a tinkerer and I like projects, plus I'm taking TIG welding classes this summer/fall, so a street fighter design may be in the future.

Until then I'll try not to bug you guys with too many questions, but I'm sure there will be a few along the way.

For now, can anybody point me in the direction of where to get a factory service manual and/or wiring diagram for this model?

Thanks.
 

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Paul-

Glad you decided to start a thread, participate and share the journey with fellow members here. Factory service manual can always be sourced at an official Kaw dealer (at a premium price), ebay or perhaps create a "wanted to buy " post here on the forum, maybe a member has one collecting dust. I think you'll need both the basic and the supplement manual, providing the latest, greatest info and would include the wiring diagram you seek as well.

In the interim, the forum wiki is a great source of information, a quick, easy "first stop".

If I may offer *opinion*....I'd get the bike repaired and legally on the road...get some miles on, become familiar with it before deciding on any radical streetfighter or other time consuming mods or changes that render the bike unrideable.

Assure the gearbox, frame, engine...all is well....BEFORE investing time, effort and money in major changes. Its undeniable the EX is a superb starter bike, but many folk sell and upgrade to different, bigger...ya never know.

Anyways, welcome to the EX forum. And pics or it......(you know)
 

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I'm looking forward to this thread. I always like to see someone bring one of these bikes back into shape.
I think for the factory shop manuals ebay might be the best bet, but there are other, readily available manuals that could be helpful. There is Clymer, Chilton and Cyclepedia, who offers both an online and printed manual. They will all have wiring diagrams. There are diagrams in the wiki here but the gen 2 version won't display.

As for oil, don't use any oil that says "energy conserving" or "resource conserving", which basically includes all automotive oil. It's not good for the clutch, which is bathed in engine oil. Motorcycle specific oil, or Shell Rotella, which is meant for diesel engines, is the stuff to use.

BTW, sounds like the elbow has healed up?
 

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It's good to see that someone wants to take their time and do things right. The factory service manual is worth it's weight in gold.
I checked ebay, and the good news is there is a base manual that you would be required to use, if you decide to go with the FSM. It's the EN400/EN450 years 85-90, and going for about $40 plus shipping, brand new.
The bad news is I couldn't find an acceptable supplement manual. They had a lot of gen1's, and a few '94's. The supplement that you would need must have your year listed on the cover. As there have been amendments made to it through the years.
The way the FSM works is you need to use the base manual in conjunction with the main part of the supplement, and then in conjunction with the sub-supplement for your specific year at the back of the book. FYI the last sub-supplement before your 04 was made in 03, so if you were to find one that went to 03, that would be exactly the same as one that goes to 04.
I paid $100 for the base manual, and another $100 for the supplement. But this was 12 years ago, and I would imagine the price has gone up. While the FSM is the best you can get, maybe it's not necessarily needed. It can be argued that your trying to get a bike that was given to you up to speed, and in my case I'm wanting to protect a $5000 investment.
Keep us posted on what you decide, looking forward to this thread.
 

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Discussion Starter #6
THanks for the kind, encouraging, and helpful words all. Here's to all of you, and I hope I can do you proud.

If I may offer *opinion*....I'd get the bike repaired and legally on the road...get some miles on, become familiar with it before deciding on any radical streetfighter or other time consuming mods or changes that render the bike unrideable.
I guess the other tricky thing about this is the simple fact that I don't yet even know how to ride. Well, I do sort of, but I'm not good enough at it to not just hurt myself. So I have a long wait of taking lessons, working two jobs, and taking welding classes all summer before I can even ride the bike. Additionally, the idea of learning bike mechanics appeals to me as much as riding, so doing some light mods seems like good times to me. So if I can't ride, why not tweak? Still, I will for sure get it running totally stock as best I can before I make any final decisions about modding it or not.

As for oil, don't use...

BTW, sounds like the elbow has healed up?
For oil I just placed an order for Bel-Ray products, having fallen under the allure of the MC Garage YouTube series. In fact I got all the liquids from Bel-Ray, because it may cost more, but I'll only have the one company to blame when something goes wrong. >:)

The arm is great. I saw my surgeon earlier this month, he looked at me putting my arm out nearly straight, almost totally locked and he said "that's awesome, nobody does that at six weeks."


be sure to drain/clean the gas tank and have a look inside
Done and done.

It's good to see that someone wants to take their time and do things right. The factory service manual is worth it's weight in gold.
I checked ebay, and the good news is there is a base manual that you would be required to use, if you decide to go with the FSM. It's the EN400/EN450 years 85-90, and going for about $40 plus shipping, brand new.
Looks like I'm just spending whatever it costs for a manual. So it goes.
 

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Discussion Starter #7 (Edited)
Manuals ordered! Found a fairly nasty looking (on the outside, insides appear clean) EN400/EN450 manual, and decently fresh 94-05 supplement from the same seller all for less than $44.

And for those who enjoy this sort of thing, here's a quick photo of how it sits today.



By the way, I guess for all intents and purposes, this is actually an '05 model and not an '04. The manufacture date on the frame says '04, but the model number on the label under the seat says D12, which would indicate an '05 model. That matches my title as well, so it makes sense.
 

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The bike looks decent. I would give you a "like" for it. But the one I gave you officially goes for the FSM, and there is only one allowed. :wink2:
 

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Congratulations on the bike!

I purchased the lifetime manual from cyclepedia and I really like it. All the colored pictures are great. If it came as a hard copy with pop-ups and coloring sections then it would be just my thing.

I agree with ducatiman, get it road legal and ride it for awhile before doing any major modifications. I bought my bike in April 2016 and only planned on doing a few mods. Here I am now and I still can not ride it.

In any case, keep posting updates and pics.
 

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From a wiring standpoint, I think the only difference you'll find between the 2004 and 2005 is (I believe) from '05-on, there was no hazard switch on the left side controls. Other than that, it should be identical.

Good stuff picking up a factory service manual set. I've got both the Clymer and factory manuals and I gotta say, the Clymer is pretty shitty in comparison, most notably when it comes to the technical illustrations.

Anyhow, it's late, I'm tired, just wanted to welcome you to the forum and the wonderful world of motorcycles!
 

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Discussion Starter #13
Here's one for you guys. I was doing some cleaning on the right hand side of the bike and noticed this was falling out.





Looks like the rubber corroded out real good, and now I need to reset it in there with a good seal. Any tips on this? Am I gonna have to buy a new "little window thing" (I have no idea what this part is for or what it means that mine fell out)? Or can I use a rubber sealant sort of thing to just "glue" it back in place?
 

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That is the sight glass to check oil level with. I think you will need a new one, or at least a new seal. I'm not sure but I think you have to remove the cover and install from the back side.
 

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That's a new one. Never encountered that before.
Looks like you can buy the sight glass from the dealer or online, part number is 52005-1009. The bad news is that the rubber is integral to the sight glass, it must be replaced as a whole. The good news is that it's cheap, about 10 bucks.
Far as replacing it, you got me. It can only go in one of two ways, outside or inside. Check the manual, see if it covers replacing the sight glass, or just remove the cover and see which way is doable.
 

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@ducatiman I took my bike down to the frame, rebuilt/modified most of it, painted it, and now I’m in the process of putting it back together. I’ll be glad I did it once I’m done, but I have not been able to ride it for so long.
 

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Full restorations can take quite some time, should not be rushed. Sounds like you are on the right track.
I feel for ya, but would imagine the excitement will build to a fever pitch as you approach completion. Any ETA as yet?

And pics or it didn't.....you know.....but in your own, brand new thread of course.
@ZeroFret sorry for minor threadjack
 

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Here's one for you guys. I was doing some cleaning on the right hand side of the bike and noticed this was falling out.





Looks like the rubber corroded out real good, and now I need to reset it in there with a good seal. Any tips on this? Am I gonna have to buy a new "little window thing" (I have no idea what this part is for or what it means that mine fell out)? Or can I use a rubber sealant sort of thing to just "glue" it back in place?
Yep, never seen that before. My bet is somebody used a harsh degreaser on it and it attacked the seal. You could try silicone, after cleaning and degreasing the bore and the sight glass, but since the glass is encased in it, you're faced wit the challenge of suspending the glass within the silicone. I'd just buy a new one.
 

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Discussion Starter #19 (Edited)
Ordered a new oil gauge window from BikeBandit, but looks like I may be waiting a while for it. In the meantime...

Time to give it some love.



First thing I started doing was rebuilding the brakes. The service manuals and information in the Wiki here were both very helpful. Basically every bolt on this thing has been frozen in place, so let me tell ya how much I love my impact driver. It's just the cheap one from Harbor Freight, and I bought adapters so that I can use it on just about any screw. Currently I am working on that slow process of pumping out the pistons, so wish me luck today. Ordered new Centric brake pads as well.

My mission this evening is picking up a good torque wrench, feel free to drop any knowledge you guys might have about buying a good one of those.

Oh yeah, and I got a Shoei Qwest helmet! Matte black and fits really nice. Totally stoked on that.

But alas, there is also some bad news. Hadn't noticed it until now, but my right handlebar is bent. Not by a lot, but it is. I'm really hoping that's not gonna be too expensive of a fix.
 

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But alas, there is also some bad news. Hadn't noticed it until now, but my right handlebar is bent. Not by a lot, but it is. I'm really hoping that's not gonna be too expensive of a fix.
Straight used handlebars can be had on ebay for between 30-50 bucks. The older (3rd gen) Ninja 250's use an identical handlebar, so that will broaden your options. The older Ninja 600's (ZX600-C) handlebars will also fit, but the ends which insert into the risers need to be shaved down a tad, they're a little too long. Once that is done, it fits and functions the same.
 
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