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Old 09-14-2013, 08:49 PM   #16
bk brkr baker
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The EX motor sure looks at home in that frame. There doesn't seem to be near fittment problems compared to the 650 Ninja/Versys swap.
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Old 09-14-2013, 09:03 PM   #17
Lizrdbrth
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Interesting. That motor is too tall for a KLR frame. It'll go in, but zero daylight between the valve cover and the top tube. You'd have to pull the motor to adjust the valves.

Never woulda thunk to put it into a DR frame.
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Old 09-14-2013, 10:13 PM   #18
Roadracer_Al
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Nice! I sure plan to follow this one since I have a DR in bits AND a Ninja 650 in my shop!
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Old 09-15-2013, 03:13 AM   #19
JerryH
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Way to go. The EX500 is a great motor. Unfortunately I found the EX500 too uncomfortable to ride very much. Nice to see that motor in something more rideable. Kawasaki makes the KLE500, unfortunately not for the U.S. market. And it probably has a detuned engine, like the Vulcan 500.
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Old 09-15-2013, 09:40 AM   #20
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The motor was not without its fitment issues, the upper shock mount cross member had to be relocated to make way for the intake & the fuel tank had to be raised over an inch to clear the valve cover, I may have to replace the front wheel with a 17" wheel for rad clearance
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Old 09-15-2013, 12:03 PM   #21
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Cross member relocated below bell mouths
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Old 09-15-2013, 03:53 PM   #22
L.B.S.
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Wow, sweet job on the exhaust looks OEM (if one can apply such a statement in so custom an application, lol)

I've never had occasion to own or ride one of Kawi's 500 twins, is there anything special about them? Any particular reason for using one? Just wanting a twin of that cc size versus a thumper?
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Old 09-15-2013, 05:06 PM   #23
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Durex like the condom brand?
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Old 09-15-2013, 06:01 PM   #24
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Quote:
Originally Posted by viverrid View Post
Durex like the condom brand?
Yes I'm looking for some Durex rubbers decals for the tank!
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Old 09-24-2013, 06:22 PM   #25
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Quote:
Originally Posted by L.B.S. View Post
Wow, sweet job on the exhaust looks OEM (if one can apply such a statement in so custom an application, lol)

I've never had occasion to own or ride one of Kawi's 500 twins, is there anything special about them? Any particular reason for using one? Just wanting a twin of that cc size versus a thumper?
No particular reason, I'm a cheapskate, I had a blown up DR650, I had an obsolete EX500 race bike & a welding machine, I didn't have a dual sport.
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Old 09-24-2013, 07:13 PM   #26
JagLite
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Cool2

Quote:
Originally Posted by yermaun View Post
No particular reason, I'm a cheapskate, I had a blown up DR650, I had an obsolete EX500 race bike & a welding machine, I didn't have a dual sport.
Those are EXCELLENT reasons for a build!
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Old 10-31-2013, 05:59 PM   #27
4play
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Old 10-31-2013, 08:25 PM   #28
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More, more, more...

Keep it coming. These type of builds are smart and show that YOUR kind of bike is out there, even if you have to make it yourself. Please keep the build record coming. I'm subscribed.
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Old 11-03-2013, 09:45 PM   #29
Straightedge
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Love the "built not bought" attitude, as well as "why not since I have all this crap hanging around".
I'm using a first gen ex500 as a project as well and feel it is my duty to direct you to ex500.com for your punishment in the use of pods and aftermarket exhaust (yes I know why you did it). The site is incredibly useful but beware: the faithful will blast you for not leaving well enough alone (I admit to being a zealot).
I'm subscribed!
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Old 11-04-2013, 06:19 AM   #30
sailah
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Not being picky just a couple observations. Is the exhaust really that close to the rear master cylinder and footpeg? If so you might want to wrap that pipe. On my FZ1 build the exhaust is a little bit close on the pegs when I rock my boot back it touches. I have my header wrapped so the boot doesn't melt. The MC getting hot and boiling the fluid would give me some concern.

Anyways, looks great, the exhaust does look killer, nice job
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