Project EX500: 'True Ninja'

[jaydub77]

Well guys,

I finally made up my mind for the exhaust, its a full 2-1 left side mount, black headers with a polished aluminium can made by jardine, and it's basically in the exact same price range as the vance and hines supersport

I got so excited when I ordered it today!

I also ordered a set of progressive springs for the front while I was at it, because the price seemed really good actaully. (and because i'm approx 190lbs I need a stiffer spring)

So now I have taken care of the exhaust, but I have to check with dynojet to see what stage kit I need to rejet for this exhaust setup, but the things I like best about this setup is:

1) I can keep the centre stand
2) the price was right!!!
3) I got a free t-shirt when I ordered it

So now I only have 3 things left to buy to get it back to road worthy shape!!

1) front cowling (I'm looking into specII for it)
2) dynojet kit
3) right front turn signal

(note: the project will still continue after these things are done, but the most important for me is to get back riding again!!!)

Well that's all I have for now, let me know what you think!

[jaydub77]

hey everyone

Well I finally had a really nice weekend to work on the bike, hit up to 30C here in vancouver and man it was hot! I would have loved to go out and ride, but you all know the story already

Well since it was nice enough I finally was able to coat the inside of my tank to seal it against rust...it is still in the curing process but will be ready for reassembly tomorrow and that is one less thing I should have to worry about

I haven't really had a good look inside the tank but from what I can see the gas tank sealer I bought really did the trick...It put a decent coat of epoxy all inside my tank and only took about a half hour to do start to finish...if anybody wants to seal their tank like this let me know and I will give you the info as to where you can get the product...I won't give it the thumbs up yet but after a closer examination of the tank I will write again with a review about how well it worked! till next time

[jaydub77]

I've used an epoxy tank sealer on my 87' ex500

I have to say it is a mixed result for me...I found that nuts and acetone really do clean out a tank really well...but the sealer itself was just a bit too thick, even in warmer weather...it did coat most of the gas tank but there are still fair patches that are left unprotected...I would recommend flushing your tank and using abrasives...but unless you really have to...i would avoid using a tank sealer

[CTGPZ]

I used the POR-15 kit on my ninja. It did an awesome job of "coating". Just didnt fill in all the holes.

[jaydub77]

well what I got was from a company by the name of caswell and was designed specifically for coating the inside of your gas tank...but it didn't quite coat as well as I thought, but considering it probably covered 70%+ of the rust I'm not completely dissatisfied either...I should also point out that there aren't any holes in my tank yet

[jaydub77]

Well I finally have a full exhaust system back on the bike!!!!

I got the jardine 2-1 full system that mounts on the left side...which means I get to keep the centre stand!!!

I only had one problem with installing it...aligning took a bit of fumbling around but that wasn't the hard part...the holes on the biggest brace were too small for the bolt where it attaches to the passenger foot-peg..so what I had to do was break out the dremel and use a diamond coated grinder bit and made the holes just a little bigger and presto!!! it fits just perfectly and look really sweet on this bike...I will post pictures tomorrow as it is dark out now and I'm done wrenching for the day...I will also try and post a U-tube vid so anyone can see how it sounds...I personally really like the sound the new pipe brings...it's smoother at idle and lower rpm's, but still really winds up when you grip a handful of throttle! and who doesn't like shiny new chrome!

I have also got new progressive springs for the front end and will be installing those next paycheck along with a new jet kit for the carbs (as there are flat spots on throttle response) and a new front brake line...then after that it's time to order the front fairing and one more turn signal and then it's back on the road again!!!!!!!!!!!!!!!!!! YAAAAAAAA!!!!!!!!!!!!!!!!!!

[jaydub77]

hey everyone,

Well I have the old girl back up and running, actually right now she runs pretty good, but I still have some tweakin left to do, but we'll get back to that later...

...soo, the new jardine RT One exhaust is on and man it's loud!!! Sounds really good though. I have also carved into the front fairing (not wanting to buy a new one), so now the bike looks kinda naked but with a small 1/4 fairing up front, kinda like the Z (oh I will be posting pics). I have also ditched the old turn signals because the old one's had nowhere to mount to anymore. So now i've got some el cheapo's mounted to the radiator of all places, again I will have pics up soon so you can check it out. Other than that I've pretty much left the bike the way it was aesthetically. because of the huge 2" wide open exhaust, I have had to play around considerably with the carbs, but I have NOT had to rejet!!! I have done the FOG airbox mod and I am quite pleased with the engine response, there is still something amiss with the carbs but I have a vacuum gauge to check things out and get things dialed back in.

Because of the way bigger exhaust outlet it also seems that that I have to do a bit of valve work as well to get the motor dialed in. At higher RPM's i'm getting some significant popping from the exhaust, and I have a feeling it is because the exhaust valves are staying open just slightly longer than they should....it's been long overdue for this engine to have it's valves checked anyways!!! (it is an 87) Oh, by the way, I have also swapped the front springs for progressive's and I have found that they are stiffer, but the 500 front end just likes to dive, though i've also been used to riding cruisers before I got this bike, maybe just a sport bike thing?

Taking it out for a ride is pretty exhilirating compared to the old honda 400 I used to have with half the horsepower, but it's still really manageable, next year I am going to move up to a 600, but i'm still gunna keep the 500 for a possible track bike!

I'm also all set up to take and MSF course at the end of the month with a friend, and it's the best school in all of Canada, so i'm pretty stocked, and I also get to ride on a ninja 500! talk about getting a good deal...anyways I will have pics up by the end of the week, hope you all like the end of stage 1 for this bike, stage 2 may be farther off but I will make it some day!

[jaydub77]

Well here are some pics of how the bike looks like at it's current state...enjoy! tell me what you think, and be honest, I can take it!

[kawturbo1]

If you like it thats all that counts. I have an EX500 and its the most fun bike I own. Not the fastest but the most fun. Enjoy it who care what other people think.

[macho man]

Hi. Can I ask where did you get the Jardine exhaust and how much it cost?
Did you make any modifications to set up?
Tks.