I blame ALL of you. . .

[OreoGaborio]

The hardest thing about jetting the EX500 is getting the airbox back in when you're done.

and a K&N isn't necessary.

And the only reason why I'm not telling you to skip the exhaust is cuz it's a great deal from another forum member... these things don't respond to power mods like other bikes.... seriously. In fact, the further you go with the EX, the harder it is to get the tuning right. Go with pod filters and you're almost guaranteeing yourself some dyno time to get it dialed in & you'll still probably end up with flat spots in the mid range.

So in short, as far as power mods go:
Keep the stock airbox
Jet it
Exhaust if you want to
Don't go any further w/o consulting a serious EX500 guru.

[Baggey22]

So I'm looking at sprockets online. I found these:
Front: http://www.kneedraggers.com/details/...0--501072.html

Rear: http://www.kneedraggers.com/details/...0--501074.html

If I get it 15/44 that will be -1 front +2 rear, I know I need a 520 chain but I have no idea how to get the correct length.

Sprockets are just bolt and go correct? I know my gauges will be off but I can adjust for that.

As for the exhaust I'm still undecided about that. It almost sounds like it's more work that it's worth

[OreoGaborio]

Borrow a chain tool to get the chain to the right length.
Your speedo will actually remain unchanged as it runs off the front wheel.
You'll benefit from jetting anyway, if you want the pipe, just jet for that.

[Baggey22]

Doc do you have a chain tool? I'd be game for visiting you some evening next week to learn how to change my sprockets. I could get the exhaust now and put it on and jet it during the winter. . . . depending on how much a jet kit is, or next week because I have lots of free time.

[Chippertheripper]

Just give her the ex and get yourself a new set o wheels. Don't forget about Buell xb's either. Very intuitive bikes to ride.

[Dichotomous]

Doc do you have a chain tool? I'd be game for visiting you some evening next week to learn how to change my sprockets. I could get the exhaust now and put it on and jet it during the winter. . . . depending on how much a jet kit is, or next week because I have lots of free time.

roadside will let you borrow their chain tool, it aint pretty and has been used by 8million people, but it mostly works.... especially if you have jason helping, but then again I belive he could swap out a chain with nothing but floss and hair cream....

on the exhaust, buy it if you want the sound, cause it doesnt sound like it will give much power, it'll make the bike about a cheeseburger and fries + 12pack of beer lighter, so skip the burger and buds and you accomplish the same, plus you stay under the radar with a quieter bike. and loud pipes do NOT save lives. but then again if you want to add them to increase the bikes sex-appeal instead of spending a lot more for a newer/sexier bike, then its still cheeper in the long run and may have you enjoy your bike more. the installation process and learning more of your bike in this manner may also increase your satisfaction with the bike.

*edit* just looked at the sale posting, for that price I think it will be well worth it considering how you will feel about the bike, the sound, the effort, the fact you can its got race bits on it..... all go a long way toward loving a bike

[Doc]

Pete is the man to listen to for the EX.

You are getting alot of advice here so I am gonna bow out.

PM me if you want my help.

[duganc1717]

roadside will let you borrow their chain tool, it aint pretty and has been used by 8million people, but it mostly works.... especially if you have jason helping, but then again I belive he could swap out a chain with nothing but floss and hair cream....

on the exhaust, buy it if you want the sound, cause it doesnt sound like it will give much power, it'll make the bike about a cheeseburger and fries + 12pack of beer lighter, so skip the burger and buds and you accomplish the same, plus you stay under the radar with a quieter bike. and loud pipes do NOT save lives. but then again if you want to add them to increase the bikes sex-appeal instead of spending a lot more for a newer/sexier bike, then its still cheeper in the long run and may have you enjoy your bike more. the installation process and learning more of your bike in this manner may also increase your satisfaction with the bike.

*edit* just looked at the sale posting, for that price I think it will be well worth it considering how you will feel about the bike, the sound, the effort, the fact you can its got race bits on it..... all go a long way toward loving a bike

Doesn't the stock EX come w/twin pipes? So the Muzzy should actually save considerably weight?

Just remember if you dump $1K into it, you could sell your bike and use the money you were going to put into it and buy a newer bike. Something like an SV 650 for around $2K.

Just a thought.

[OreoGaborio]

Pete is the man to listen to for the EX.

Nahhhh, just spoutin off what I've learned from the EX Mafia up at the track.

[Baggey22]

I'm REALLY liking the idea of the sprockets and exhaust on my bike. I love my EX, she's been great to me and I think riding her another season or two and doing some track days and getting lots more experience on that bike will be WAY more beneficial than just up and buying a newer more powerful bike.
I'm gonna order those sprockets like. . . . . now and then see about getting that chain tool. Doc, I would enjoy your help with it all because if I'm going to be tearing into the bike I'd rather just do it once and have someone help that actually knows what they're doing.
So what should I look for concerning the jet kit?

[Baggey22]

So I just got the deal of a lifetime. I called a local motorcycle place (right in Morriseville) and asked if I could borrow a chain tool because RoadSide Marine is a 45 minute drive for me. The guy asked what I was doing and I told him about doing sprockets on my EX500 and we talked about pricing and whatnot. Apparently someone came in a few days ago that was going to do the same thing and had already ordered the sprockets and new chain, but then wrecked his bike while being drunk and stupid. So they're going to give me the sprockets and chain for a small discount because they can't return them. I'm going to drop my bike off tomorrow and have them install them (that was the "catch") and I'll pick it up on Monday.
I'm getting the front 15 tooth for like $18 and the rear 44 tooth for $32. Then it's like $50 for the install.
Now all I gotta do is pick up that exhaust this weekend and I'll be set.

[SRTie4k]

Sounds good, an exhaust should be a very easy install. You should need only basic hand tools.

[Baggey22]

It's not the install of the exhaust I'm concerned about. It's getting the bike to run correctly once it's installed that I'm concerned with.

[duganc1717]

Some info from Muzzy's tech department.



10-01-09

The stock system weighs about 24lbs the Muzzy full system 8lbs and will develop about 10% hp gain.
To order please call Curt @ 541-385-0706 ext-107,Muzzys pays the ground shipping on retail orders over $300.00. Thank you for contacting Muzzys

Curtis Dorn
Sales & Technical
541-385-0706 ext-107

At 07:39 AM 10/1/2009, you wrote:

Hi,
I was trying get some information about a exhaust for a Kawasaki EX 500. Would now the weight difference between the stock exhaust and a Muzzy Stainless exhaust system w/aluminum canister?

Also would you what can be expected for horsepower gains with proper jetting?


Thanks for your time.

Curtis Dorn
Sales & Technical
541-385-0706 ext-107

[Slyder]

On your EX, does the speedo read off the front wheel? Or is it newer with an electronic sensor / rotor on the counter shaft? If it's off the front wheel, you shouldn't get any increased speedo error...unless you changed the series of the front tire, as in 120/60 or 120/70.

Changing teeth on the sprockets won't change your fuel economy at all, IF you ride the bike the same. Mine is happy cruising at 5-6 grand and gets about 37 mpg. I've gone -1 +1 and it gets the same mileage.

If you're going to buy an air filter, get a BMC. If you're considering a K&N filter you might as well put some sand in the airbox, hold the throttle wide and hit the starter

[Baggey22]

Are there any places around (Johnson, but I'm used to traveling far distances for this kind of stuff) that will properly jet my bike for me?
Anyone have experiences with places?

[802er]

So I just got the deal of a lifetime. I called a local motorcycle place (right in Morriseville) and asked if I could borrow a chain tool because RoadSide Marine is a 45 minute drive for me. The guy asked what I was doing and I told him about doing sprockets on my EX500 and we talked about pricing and whatnot. Apparently someone came in a few days ago that was going to do the same thing and had already ordered the sprockets and new chain, but then wrecked his bike while being drunk and stupid. So they're going to give me the sprockets and chain for a small discount because they can't return them. I'm going to drop my bike off tomorrow and have them install them (that was the "catch") and I'll pick it up on Monday.
I'm getting the front 15 tooth for like $18 and the rear 44 tooth for $32. Then it's like $50 for the install.
Now all I gotta do is pick up that exhaust this weekend and I'll be set.

Lucky.... Was it S&S? I'm thinking of seeing if they will install my new chain/sprocket. I have no workspace at the moment.

[Baggey22]

Yes, it is S&S. I'm gonna ask about the jetting while I'm there tomorrow too.

[Baggey22]

Update:
I got my bike back from S&S. Sprockets were done and it made a good difference. Haven't really opened it up because I only drove it home but got stuck behind a van the whole way and the roads were moist so I didn't want to be stupid.
I also picked up my exhaust this weekend and ordered a jet kit from S&S. As soon as that comes in I will either get it installed there or have someone help me do it.