EX500 1992 Rebuild

[adidasguy]

I have a stock pile of GS500 exhausts.
I have a brand new Motad for the Ex500. Just waiting to put it on.
Then there are a few locals then the EX forum wanting it.

[willi777]

 Bike is looking sweet Adidas. The stock mirrors do a better job of blocking wind from your hands than actually providing any rear view. I use CBR929 mirrors and stalks in the EX500 mirror mount- provide better rear view. Others have used the 08+ up Ninja 250 mirrors, and the Ninja 650 mirrors.  The stock blinkers have a tendency to punch through the fairing when you drop the bike- that's why most people replace them with flush mounts.

[adidasguy]

Finally made more progress.
Engine bars are on.
Removed the Muzzy tonight with help from BrianRC and put on the Motad (from the UK) and now was able to put back a center stand. Muzzy doesn't allow a center stand. The Motad exhaust does.
Motad is a little quieter and deeper than the Muzzy. We like it!

[yamahonkawazuki]

Very impressed 

[codajastal]

What he said ^^^

[adidasguy]

Rode the EX to the office today. MUCH MUCH MUCH quieter than the Muzzy. I can hear the clacking of the engine and some bit of plastic rattling.

I like it! I hate loud bikes unless I am trying to annoy the anal retentive gravel raker at the end of the alley. Thumper - the 1973 smelly loud 2 stroke does that quite well. Just wait until Scutter is running!

After a few days, I'll re-tighten the bolts on the exhaust. It was a bit of a biiitch to get on so it needs to settle in. The GS500 Motad fits so easy. I hate working on a Kawasaki - not nearly as simple as our GS500's.

[dB-tje]

Nice to see that bike getting fixed nice job.
I see you have enough bikes to chose from when you want to go for a ride

[adidasguy]

Nice to see that bike getting fixed nice job.
I see you have enough bikes to chose from when you want to go for a ride

1 bike short of one for each day of the week. 

[adidasguy]

Locating the last few parts. New OEM NOS side covers (1898, ebony with red decal) $100 each. Whatever. Figuring the time to tape it off, paint it and clear coat it, meh, might as well buy them. I'd rather be riding or helping someone else fix their bike.

Cowling will have to be repaired. NOS cowling is $799. Targa after market not as nice.

Dealer will have a fixed ASV clutch lever. No one knows why it is wrong, but the bolt hole needs to be 8mm and it isn't on the part. ASV is sending the dealer a bushing with a larger bolt hole so that should fix it.

I know I'll never get all my money back from this project, but I still like doing it. Rides like a turd compared to Junior or Phenex.

[JAS6377]

... Rides like a poop compared to Junior or Phenex.

I think the correct term is "tird" lol. Anyway, you should definitely post a video of the exhaust. My CBR friend's dad has an EX with D&D slip ons. It sounds pretty good, but it is on the loud side.

[adidasguy]

There is a profanity filter. I had t.u.r.d. and it changes it to turd

[Wagoneer]

I know what you mean about them riding like poop compared to the GS. It definitely doesn't compare to the GS in terms of quality. It feels cheap compared to the GS. My buddy has a EX500 with full exhaust, and if you're a big dude like me, I'd take the powerband of the GS's engine any day compared to the EX.

Even the ninja 250's seem better quality than the EX500's... not sure why.

[yamahonkawazuki]

... Rides like a poop compared to Junior or Phenex.

I think the correct term is "tird" lol. Anyway, you should definitely post a video of the exhaust. My CBR friend's dad has an EX with D&D slip ons. It sounds pretty good, but it is on the loud side.

could always use an Umlaut as in Türd ( or other accented U

[adidasguy]

Got in a NOS right side panel. Looks great! I just located a left side panel on ebay so that's on its way. Now to fix the cowling and she will look real darn purdy like!

[yamahonkawazuki]

There is a profanity filter. I had t.u.r.d. and it changes it to poop

Umlaut for the win Eh? try Türd lol