where to start?

[catch2otwo]

ok so i picked up mike's 88 ex500 this weekend. its been sitting for two years. i haven't pulled it out of the truck yet but i figured id garner some opinions today. this is the description in the ad

"The bike does not start, when I asked the ex guys they said it was something about the brushes and magnets for the starter that need to be cleaned. When you try to start it you can hear something spinning but that's about it."

some of the other things i noticed was the front brake rotor needs to be replaced and the caliper needs to be rebuilt. not sure if the rear brake works.

here was my to-do list.

1. pull off carbs - clean
2. drain fuel
3. remove key cylinder

any ideas on the key cylinder? i figure i can just rig up a switch for on/off and just have a push button start? just going to be a track bike so no worries about needing a key.

[bigred875]

4. pull starter, clean brushes?

[catch2otwo]

not familiar with this stuff. im pretty confident with a wrench. is cleaning the brushes a fairly common thing to do? i need to find a manual for this thing.

[eboos]

any ideas on the key cylinder? i figure i can just rig up a switch for on/off and just have a push button start? just going to be a track bike so no worries about needing a key.

I was going to do this with my bike too. My ignition switch is just a simple 3 way switch that shouldn't be a problem to change.

[catch2otwo]

I was going to do this with my bike too. My ignition switch is just a simple 3 way switch that shouldn't be a problem to change.

good to hear. cant wait to dig into this thing.

[McBiggity]

i may have a manual still laying around for my old ex500.
I'll see if i still have it, if so, it's yours.

[catch2otwo]

hey thanks biggi. ill shoot you a few bucks, let me know.

[Pittenger5]

I have an electronic copy of the manual if you cant find a paper copy.

[OreoGaborio]

http://www.cheapbastidracing.com/stu...ice_manual.pdf

It's for the pre '94, but they're pretty much the same, engine wise. (except for the heads)

[catch2otwo]

excellent. thanks guys

[McBiggity]

sorry, just took a look through the garage. Don't have it anymore. It may have been lost in the move

[SVRACER01]

a lot of guys rig the key switch up the kill switch.
off= off
run= equivalent of turning on key.
its pretty easy actually

[Punjistick]

You can eliminate the turn signal controls by disconnecting the plug under the tank and inserting a piece of wire for a jumper. You can then use some safety wire and a washer to make a new choke. I have seen this on several EXs.

[catch2otwo]

a lot of guys rig the key switch up the kill switch.
off= off
run= equivalent of turning on key.
its pretty easy actually

good idea sv. i like that. i need to get the tuono out of the garage so i can start working on this thing. pete i got that manual from your link thanks!

[butcher bergs]

is cleaning the brushes a fairly common thing to do?

Cleaning the brushes is tit as long as the starter is serviceable. Just make sure everything's completely dry before you put juice to it.

[OreoGaborio]

pete i got that manual from your link thanks!

Good, I tried emailing it & gmail said it was too big

[catch2otwo]

o well thanks anyway. i have to dl it again on my home computer since it wont dl on this work computer. hopefully put some gas in it and throw a battery in it once i rig up the switch and see if i can bump start it.

[CEO]

a lot of guys rig the key switch up the kill switch.
off= off
run= equivalent of turning on key.
its pretty easy actually

That's a great idea.

[catch2otwo]

ok. ready to put fresh gas in the tank. one problem. dont have a key for the tank. anyone know where to get one of those nifty keyless gas caps for it? and will i be able to undo all the bolts for it and take the stock one off without the key?

[JohnnyV]

There will be a screw under the cap, so no.

[catch2otwo]

hmm so any ideas as to getting this thing off?

[Punjistick]

jam a straight-blade screwdriver in and turn it?

[catch2otwo]

jam a straight-blade screwdriver in and turn it?

hope it didnt come to that. but it doesnt look like i have a choice.

[Punjistick]

there is a little latch at the front of the cap (12 o'clock position as viewed from the seat) if I recall correctly. You might be able to push something in between the tank and the cap to get it to open but I'm not sure.

[SVRACER01]

yeah even if you get all the bolts out generally the LOCK (ie:latch) hooks into the tank itself. screwdriver it is. OR...there may be a # on the bottom of the ignition, this will be the key # and you may be able to just get a replacement key if so desired