EX500 Wiki

- Welcome to the "new"  -

This is at the moment, a single-man operation, open to community collaboration; trying to copy-paste all the data from the original EX500 wiki off the wayback machine snapshots. The original wiki was integrated with the forums, so some text may suggest this. I have/will edit what I notice sounds weird, but you can't catch everything. [Bracketed text indicates my own comments, usually noting a difference from the original content, or credits from the original text]

Contact littleprince on the EX500 Forums if you find this and want to help out. Edit as you wish, this is open as a collaborative effort. Contact littleprince on the EX500 forums if there is an issue only the wiki starter can solve.

Wayback Machine Original Wiki Archives

Get Started Here:


Frequently Asked Questions about the EX 500/GPZ 500/Ninja 500
Service Manuals - a list of DIY service manuals available for the Ninja, GPZ, EX 500.

What kind of fuel should I use? - regular gas. If you're wondering why read this.

Tool List - what tools are required for maintenance. Key Replacement - how to replace your ignition key.
 * Accessories every DIY mechanic should own.

Electrical troubleshooting - a dead battery is the most common cause of electrical issues. [Not archived by wayback machine]

Bolts, bolts, and more bolts - an explanation of bolt specifications.

General EX500 information

 * Maintenance Schedule - a list of scheduled maintenance tasks from the owner's manual
 * Engine Numbers - Details about the build number found on the engine

Storage and Cleaning

 * Winterization and Storage - putting the bike away
 * Winter Inspection and Maintenance - taking the bike back out
 * Tips and Tricks to Cleaning a Motorcycle

Measurements

 * Specifications - Manufacturer specifications for the Kawasaki Ninja 500 R/GPZ 500/EX 500
 * Torque Specifications
 * Tire Sizes[Page nonexistent on original]
 * Hose Sizes

Generation 1 EX-500 (1987-1993) vs. Generation 2 Ninja 500/GPZ 500(1994-2009)
Kawasaki called the first generation 500 the EX-500 in North America and GPZ 500 S in Europe. The second generation 500, introduced as a 1994 model, was not a complete redesign but a design change. The second generation 500 was called the GPZ 500 in European markets and the Ninja 500 in North American markets. They are the same bike. At some point Kawasaki marketing changed the name of the Ninja 500 to the Ninja 500 R. This was done because R is one of the faster letters in the alphabet, it does not imply any actual changes to the bike.
 * The Gen1 and Gen2 bikes have some differences between them. Purchasers and owners should be aware of these differences for maintenance, upgrades, and ordering compatible parts and accessories.


 * Interchangeable Parts - between Generation 1 and Generation 2 bikes
 * Difference in Gen 1 EX500s (pending)[unavailable] - aside from simple parts incompatibilities, the Gen1 has a 16" wheel vs. the 17" of the Gen2, a fork oil screw, 36mm vs the Gen2's 37mm fork diameter, and solid bars that do not accept bar-ends (unless you drill and tap them).
 * Recommended modifications to Gen 1
 * 1st Gen CCT Replacement with a stock Gen 2 part.
 * Gen 1 flywheel replacement[Not archived] with a slightly modified Gen 2 part.
 * Gen 1 transmission replacement[unavailable], which can have a fault where the bike will pop into neutral while engine braking in second gear. Substitute a Gen 2 transmission.

Alternate Parts

 * Non-OEM Parts[unavailable] - Substitute parts which may be desirable due to cost or availability

Maintenance how-to and modifications
Note these how-to's are best used in conjunction with one of the DIY Service Manuals. Bolded items are recommended to all 500 owners except where noted.

Brakes

 * Brake Caliper Service[incorrect redirect]
 * Rotors and Pads[not archived]

Carburetor, Exhaust and Fuel System

 * Carburetor Maintenance
 * Carburetor Refresh
 * Synching Carbs - perform FOG airbox mod and valve adjustment before synching carbs, not after
 * Fuel Filter Installation - An optional aftermarket $5 part to prevent carburetor problems.
 * Air Filter Cleaning
 * Gas Tank and Petcock - fuel flow issues
 * Petcock rebuild - replace the perishable parts for a third of what a new OEM petcock costs (pending)
 * Where do these hoses go? - hoses on top of engine
 * Hose diameters - Detailed information about specific hoses/lines

Modifications

 * FOG's Airbox Mod
 * Exhaust - adding an aftermarket exhaust
 * Removing the California Emissions - for those not obligated to have the Evaporative Emission Control System
 * PAIR Removal - Removing the PAIR system from the EX500 engine

Electrical, Gauges and Lights

 * Wiring Diagram
 * Electrical Connectors - Pictures of various wiring plugs to show wire colors and locations
 * Charging System
 * Battery Maintenance
 * Headlight Adjustment and Maintenance - Adjusting the headlight aim for optimum nighttime visibility.
 * Removing Metal Backing Plates From Stock Front Turn Signals - - Do this to prevent fairing damage in a tip over.

Modifications

 * Flasher Replacement - how to fix the fast blink after switching to LED turn signals
 * Flush Front Turn Signal Mod
 * Gauges - replacing gauges
 * Headlight Tint
 * LED Replacement - how to regain an extra 50 watts from your electrical system for heated gear or other applications
 * Shortening Stock Turn Signals - how to make your existing blinkers sit a little closer to the bike
 * Switched Accessory Power - how to build a cheap and easy switched accessory supply power circuit for heated grips or other aftermarket accessory
 * Streetfighter headlights and turn signals
 * Tail Light Integration
 * Tail Light Turn Signal Integration
 * See I want to make my bike into a streetfighter at faq.ninja250.org for many conversion-part options which work equally well for the 500

Engine and Drive Train

 * Replacement of the Cam Chain Tensioner - replace the problem prone cam chain tensioner in first generation bikes with one from a second generation bike
 * Clutch Springs Replacement
 * Clutch Cable Maintenance - lubing the clutch cable, should be done at least once a year
 * Chain maintenance
 * Chain and Sprocket Installation
 * Final Drive and Gearing
 * Installing a New Chain and Sprockets
 * Performing an Oil Change - annually
 * Oil Filter Cross Reference
 * Valve clearance adjustment - every 12,000km or 7,500 miles
 * Spark Plug Installation and Maintenance
 * Where do these hoses go? - hoses on top of engine
 * Replacing Balancer Shaft Seal - what to do when your engine starts weeping oil on the right side
 * Replacing oil pan - Replacing the oilpan, in case you strip your oil drain bolt
 * Hose diameters - measurements for replacing all perishable hoses

Fairing, Frame, Handle Bars, Luggage, Mirrors, etc.

 * Motorcycle Luggage - pretty much essential
 * Handle bar modifications - tips for reducing handle bar vibration, increasing handle bar comfort, and raising or lowering handle bars
 * Heated Grips and Gloves Overview
 * Portable Heated Grips - Review and installation of portable heated grips
 * Installing Heated Grips - How to install heated handlebar grips
 * Frame Sliders and Engine Bars - installing tip over protection for the Kawasaki 500. A great preventive measure especially for newer or shorter riders - they will usually pay for themselves in spared scratches and damage.
 * Mirrors - Modifying the mirrors to get a better rear ward view.
 * Helmet Lock Usage and Mods - move the stock helmet lock to a more practical location
 * Removing Metal Backing Plates From Stock Front Turn Signals - Preventive measure to protect your fairing from an accidental tip over.
 * Colors per production year
 * Body work - fairing repair
 * Seat repair and replacement (pending)
 * Windshields
 * Stebel or Wolo Air Horn Install - make your 500 sound like a freight train

Suspension

 * Fork Maintenance - how to disassemble forks and replace fork seals
 * Setting Suspension Preload - adjusting the suspension for your body weight.
 * Unitrak Bushings - Dimensions For Rear suspension Bushings

Modifications

 * Cartridge Emulators - Information and installation information for Racetech cartridge emulators and fork springs
 * Upgrading the Suspension - making the 500 handle like a more expensive bike
 * Adding a Fork Drain Screw - Early bikes include a fork oil drain screw, but newer ones do not
 * Switching Out the Dog Bones - You can use shorter or longer dog bones to raise or lower the bike, respectively

Tires and Rims

 * Tire Choices - Overview of replacement tire options for the EX-500
 * Wheel Removal and Installation
 * Changing Tires

Modifications

 * Reflective Tape for Rims and Chassis

Troubleshooting

 * Fault Finding
 * Common Problems
 * Safety Switches Test Procedure

Gear and Accessories

 * Rider Apparel Overview - an overview of motorcycle gear options. Some advice for shopping for gear.
 * Gear Reviews - gear reviews by site members or add your gear (Google Docs Spreadsheet)
 * Hot Stuff - Heated Gear and Grips - an overview of heated gear, grips and muffs.
 * Cycle Gear and Parts Sources - a list of on-line retailers
 * Motorcycle Luggage - making the 500 a Sport Tourer
 * Electronic Accessories - GPS, helmet intercoms, cell phone interconnection, etc.
 * Video and Photography - Motorcycle camera mounts, making riding videos, etc.

Riding Tips and Technique

 * Basic Cornering Skills
 * Shifting Techniques
 * How to Bump Start a Motorcycle - how to start you bike with a dead battery

Legal

 * Importing a Motorcycle to Canada - the process of bringing a cheaper US bike to Canada

Useful outside links

 * Motorcycle fork diameter chart at Scandalon.com - useful for finding Ninja-compatible fork-mounted components off of other makes of bike.
 * Kawasaki's Vehicle Information Portal - parts diagrams, manuals, and specifications.
 * Shallowsky's Modifying an EX500 - not all his opinions mesh with the forum, but useful perspective

