EX500 1992 Rebuild

[adidasguy]

She comes home tomorrow.

I saw her today.

She runs really great. New tires (tyres for the non-US people), chain, sprockets, handlebar controls, bars, fluids, Shorai battery. Carbs cleaned and sync'd.

[yamahonkawazuki]

i KNOW you consider me weird lol, but i had always enjoyed working on the ex bikes cant wait to see a video walkaround

[codajastal]

Cant wait to see her

[adidasguy]

Picked her up today. She rides really well. Different feel than a GS500. I think because the pistons are not 180* from each other, as one guy at the shop tolld me. That Muzzy exhaust is really loud.

Here he is being taken out of the storage shed by the mechanic.


and close ups. Nice with all new-old-stock controls. Fairing bracket will be replaced so it is not mushed to the left. Fairing will get painted. Not sure what color. Maybe flat black? Everyone does it so it must be the right thing to do 
Talk about worthless mirrors: I might as well aim it at my balls. Oh, wait, that's about all the mirrors can see - that or the sky. I will have to get better after market mirrors.
The left side looks OK. It was low sided on the right side.




There's the reason it sat for 6 years. I guess the owner really got spooked.

[adidasguy]

Mirrors: crappy. Will need after market ones that are linger.
Springs: Same as GS500. Fortunately I have Sonic's and they are the same as the GS500 for the EX500.

Otherwise, interesting. The weak springs and 16" front tire (tyre) make it want to dive into turns.

It will be an interesting bike to restore.

I do like that the headlights are off until the bike is running.
The 4-way flasher (aka PARK) of the key is past the ON. No chance f leaving in park when you turn the bike off (as with the GS500).
You can start bike in neutral without holding in the clutch. I like that. I'll make that mod on my GS500's. handy when working on bike or needing to fiddle with the choke when starting the bike.

[codajastal]

You can start bike in neutral without holding in the clutch. I like that. I'll make that mod on my GS500's. handy when working on bike or needing to fiddle with the choke when starting the bike.

Bike is gonna look great

I have never had to pull my clutch in when starting my bikes? All 3 Suzukis can do this not just the GS's but also the GSXR.
Must be an Aussie thing?

[adidasguy]

Gs500's have the start button in series with the clutch safety switch. If you can start a GS500 without pulling in the clutch, the safety switch has been bypassed. You can do that in the headlight bucket (89-00) as that's where the clutch switch connects. Or short the wires at the switch or stuff crap in the switch housing to shirt the contacts (if the older one 89-95 I think).

[MekaniX]

It would be easy to wire in a relay to bypass the clutch switch when in neutral.

[adidasguy]

It would be easy to wire in a relay to bypass the clutch switch when in neutral.

My thoughts exactly - which is what I will be doing.

[codajastal]

Just seems a little bit odd that all 3 bikes are the same even though they are different years and came from different people? I have had a look inside both headlight buckets and everything looks to be standard.


Sent from my iPad

[adidasguy]

Just seems a little bit odd that all 3 bikes are the same even though they are different years and came from different people? I have had a look inside both headlight buckets and everything looks to be standard.


Sent from my iPad

People break clutch levers. When  they replace them, they usually break the safety switch. They get pissed. They short it out somewhere. Trace your safety switch wires and see where they go. See if the switch is shorted out.

.....and 2 of my used bikes no, make that 3 of them, had the safety switch shirted or farkled so it didn't work. I think that is 3 out of 4?

[codajastal]

Ok cool and thanks for the info. Sorry for the thread jack, back to the topic at hand.


Sent from my iPad

[adidasguy]

Finally did some work today.
Replaced the rear plastic with a good one. The red stripe needs to be added to the side plastics.
Added a Renntec rear carrier.
Put on OEM new old stock front turn signals and threw the fugley flush mount imitation carbon fiber ones in the trash.

Do you think this front fairing bracket needed replacing?


Some views today at the Bike Cave.




Horray! both mirrors and REAL turn signals.

[jacob92icu]

Its looking really good in person everyone!

And I really like the sound of the muzzy haha, real loud and throaty. Not as throaty as the one he has on junior though. V&H

[yamahonkawazuki]

Liking what i see thusfar. BTW in the shed shot a bit ago, did i see a gr650? looked ALOT like the one i had lol

[adidasguy]

Liking what i see thusfar. BTW in the shed shot a bit ago, did i see a gr650? looked ALOT like the one i had lol

The shed shot was at the shop that did the basic m\engine tune up. I don't like working on Kawasaki engines so I farmed it out.

[yamahonkawazuki]

Liking what i see thusfar. BTW in the shed shot a bit ago, did i see a gr650? looked ALOT like the one i had lol

The shed shot was at the shop that did the basic m\engine tune up. I don't like working on Kawasaki engines so I farmed it out.

Aye i remember that part. ( you mentioned it )

[adidasguy]

Now looking for a good front fairing. That one has most tabs broken and a few cracks. Though it is ridable now.

NOT AS MUCH FUN AS A GS500!
The GS500 is a joy to ride. This thing feels like a tird. (spelled with a "U" and it gets changed to "turd")

[Bscanlon64]

Ill trade ya a stock GS can for the muzzy!

[jacob92icu]

He is waiting for the muzzy to be spoken for on the ex forum.