where to start?

[LaRNZ]

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



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.

send me the ignition, i can fit keys to it, jus gotta pay the shipping

[catch2otwo]

send me the ignition, i can fit keys to it, jus gotta pay the shipping

i already broke it into little pieces

[McBiggity]

Best pic i could find, but my first ex had a basic automotive tach. Also had a toggle switch and push button start, no key.

[catch2otwo]

Best pic i could find, but my first ex had a basic automotive tach. Also had a toggle switch and push button start, no key.

k cool, so an auto tach will work.

ok found another wiring diagram in the book just on the ignition circuit. looks like if i connect the white wire (regulator) to the yellow wire (goes into 4 pin connector on the kill switch) it should complete the circuit and leave the kill switch as the on/off switch.

[catch2otwo]

k a little more progress
got the carbs off, cleaned the chain, and finished wiring. dont know if it works yet, battery is dead.





overall, everything looks pretty clean. carbs still had fuel in them so hopefully theres nothing clogging anything up.

[McBiggity]

take the carbs completely apart. Clean the pilot jet very good. The pilot jet clogging is a known issue w/ Ex's

[catch2otwo]

take the carbs completely apart. Clean the pilot jet very good. The pilot jet clogging is a known issue w/ Ex's

will do. thanks for the tip

also, what size and brand is that tach?

[CEO]

That left handgrip is not in the right place, especially for a track like Loudon!!

I saw you mention that you cleaned the chain... but you should replace that chain and sprockets. By the looks of it they are wayyy past gone.

Looks like a fun little project. You'll get it running, just time and patience and a few bucks should be all it takes

[catch2otwo]

That left handgrip is not in the right place, especially for a track like Loudon!!

I saw you mention that you cleaned the chain... but you should replace that chain and sprockets. By the looks of it they are wayyy past gone.

Looks like a fun little project. You'll get it running, just time and patience and a few bucks should be all it takes

ya, i was going to move the left hand grip out, im not used to having my hands that close in.

on the chain and sprockets. they just seem gummy. just looks like a little surface rust. doesnt seem like the links are loose or anything. still feels pretty stiff. but then again, i dont know how long its been run before it was put away. think i still need to replace them?

[Punjistick]

It's an EX. As long as the chain is not binding and it's safe, who cares.

[McBiggity]

will do. thanks for the tip

also, what size and brand is that tach?

I don't remember any details on the tach. I got rid of that bike 3 years ago.
I would say it was about 4" diameter.

[kamikaze]

The front rotor looks more rusted than george bush's brain. I think you would need to replace the entie bake caliper assembly.

I was talking to a few folk and most of them suggested replacing the spockets along with the chain

[Punjistick]

Since it's going to be track only, you're gonna want the EBC rotor anyways. Also you can just buy a caliper off ebay from a newer EX instead of spending the time on rebuilding the caliper you have. It's probably about the same price as an o-ring kit.

[Paul_E_D]

Good god, that brings back memories of my first race bike. 88EX It was HIDEOUS, but I had fun with it. I gotta try to find some pics...

[boosten lebaron]

might want to check the valves real quick while you got it that far apart. its only a few extra minutes for a lot of piece of mind. get a cheap lawnmower fuel filter for that thing too.

[Punjistick]

might want to check the valves real quick while you got it that far apart. its only a few extra minutes for a lot of piece of mind. get a cheap lawnmower fuel filter for that thing too.

+1 I've got an '01 and the paint is flaking all around the gas cap opening. Lot of little bits that want to clog things.

[catch2otwo]

hope everyone had a nice thanksgiving. now, got the carbs apart and cleaned everything. here are a few pics







now question time. the two slides. i cant figure out what makes them move. the only carb ive ever had apart is from my dirtbike. now when you twist the throttle on that, the cable pulls the slide up. on these carbs, twisting the throttle opens up the butterflys. i dont see any linkage or anything to move the slides.

question two. in the pics below, what is the thing im sliding over? in the second picture you can see the gold rod.

question three. one of the gas inlets is plugged off by the big black cap. why is that? the other side has a gas line running into it, but the other carb is capped. i dont see any way gas can make it to the other side.





note: the safety wire in the pics is attached to the things im asking about in question 2. but when i got it, its not saftey wired to anything, just kinda there.

overall, the jets were all cleaned and all the passage ways blasted. lots of crud came out of the gas inlet when i sprayed carb cleaner into it. both needle jets were nice and sharp, nothing was nicked or damaged.

[Punjistick]

The safety wire is attached to the choke. Not sure about the other stuff.

[catch2otwo]

The safety wire is attached to the choke. Not sure about the other stuff.

ooo ok thanks

[FTMS]

Air veloctiy is was moves the slides. On the air box side of the carb there is a large opening that goes into the diaphram chamber. Be carfule with the diaphram on the slides, they don't like chemical cleaners. When you put the carbs back together, take compressed air and shoot it into the the opening to the diaphram chamber to see if the slides are working.

[catch2otwo]

Air veloctiy is was moves the slides. On the air box side of the carb there is a large opening that goes into the diaphram chamber. Be carfule with the diaphram on the slides, they don't like chemical cleaners. When you put the carbs back together, take compressed air and shoot it into the the opening to the diaphram chamber to see if the slides are working.

cool. i was real careful with the diaphrams, they looked real sensitive. anyone have any idea why one fuel intake was capped off?

[McBiggity]

Not sure, but both my ex's were like that. Had no issues.
I don't think that side is a fuel inlet. I'd check the manual to be certain.

[catch2otwo]

Not sure, but both my ex's were like that. Had no issues.
I don't think that side is a fuel inlet. I'd check the manual to be certain.

ok i just found it strange. the manual is at my gf's house thats why i asked before checking it. ill look it up when i get over there. just seems strange to me that fuel isnt going to both from the same spot. maybe putting fuel to both will give it 100 hp?

[boosten lebaron]

fuel is feed threw that big line. those are the vacuum lines. one is capped the other goes to the petcock assuming you still have one. no fuel will flow from the tank without a vacuum source. that center black tube is the fuel overflow. most just leave it off.
looks like youve got a bit of varnish in those carbs. just let it soak in something for a while.

[catch2otwo]

fuel is feed threw that big line. those are the vacuum lines. one is capped the other goes to the petcock assuming you still have one. no fuel will flow from the tank without a vacuum source. that center black tube is the fuel overflow. most just leave it off.
looks like youve got a bit of varnish in those carbs. just let it soak in something for a while.

thanks, so all the lines look fine?