Kawasaki ER 500 - Backyard Bike Project - Episode 8

[@motorcyclerefurbishment8162]

As soon as I see you have a new video I get the kettle on, time to enjoy 2 pleasures. I was amused about the use of the hairdryer. it looks like it's going well, exhaust studs that unscrew, you are so lucky.....

[@chrisroake1687]

Many years ago my grandfather (as a youngster) used to have the early morning job of putting hot coals in trays under lorry engines to warm them up before starting them with the handle before the drivers would arrive for work. Imagine the H&S lot seeing that nowadays 😂

[@ALARAiswise]

Another great video. A real 'old school' diy mechanic. Hammering the screwdriver through the oil filter - love it. I just hope those carbs are not gunked up with old evaporated unleaded !! I found my ER5 was very sensitive to airbox changes. Those CV carbs can be difficult to tune on part throttle. I doubt it would run at all with out the air box. The snorkel on the airbox seems very restrictive. I drilled a hole in my snorkel to let more air in - big mistake, part throttle running was awful. Kawasaki must have spent a lot of time tuning the airbox and carbs together. Any changes to the air flow, back pressure and resonances created will result in worse running unless you really know what you are doing. And, yes the breather design of the airbox allows petrol into the sump if the carb floats leak !

[@dirtygarageguy]

ALARAiswise Thanks for the heads up, I mostly leave the airbox arrange well alone, as you said these bike companies tune the shite out of them to get better numbers etc. Carbs will be coming off at some point, i'll change all the gaskets and if the price is right some new jets as well. As for the 'Old School' DIY thing, thats what I'm going for so some of the young lads can see what can be done without all the tools etc. Poeple seem to be put off if they don't have the correct tool. Sure its IS the best way to do things but not the only way. - Thanks for the comment - matt

[@BB-mu5ov]

If you don't have the tool find another way or make the tool. I've smashed screw drivers through oil filters and people always kick off about it. It's not as if it's getting used again so fuck it. Love the back yard stuff.

[@jmn356]

Coming to this late - but just a week into owning a ER5 after a long gap in riding / owning bikes. Looking forward to using your vids as a guide. my first job is a leak of coolant from the cylinder by my left leg.. ordered O rings and hoping they fix the issue.. the fun begins in fitting them when they arrive. Your visual of a lot of work on here will really help though. Thanks

[@dirtygarageguy]

No worries mate, this is exactly what these videos are for. The project is still ongoing. Are you sure the 'leaking' isn't from the spark plug drain?

[@jmn356]

I haven't established to be honest - just it was coming out of the tiny hole on the side of the cylinder (by left leg) but that section seemed dry yesterday after a run but fluid on my leg and splashed down on the pipe. I'll have a look at the spark plug drain - I didn't realise till I watched your vids the plugs were in there as only got her last week - just need it to stop raining so I can have a nose. Thanks again :) Have a lot to learn so the vids will defo help.

[@dirtygarageguy]

no worries mate, you have to keep that hole clear and take that extra time during winter. It can become blocked by leaf debris and shit. It will eventually corrode your pulg and HT lead.

[@CalmBiker]

Wife's hair dryer? You're brave :-D I use a dog dryer for the bike nowadays I suspect that would do the job. That bike has definitely seen a winter or two. It will be interesting to see the end result.

[@dirtygarageguy]

Yeap, good thing was it was the back up hairdryer. As I said a heat gun would do the job also and so on..... Moving on abit of a pace now with the old ER5 - you've only got another 50 odd episodes to go lol

[@mariusm5187]

I had issues with getting my oil filter off too. That exhaust is really in the way.

[@dirtygarageguy]

Mariusmssj M Yeah but the best design in removal respects but everything wit hengines is a compromise

[@mariusm5187]

I see you went for Hiflo by the best filters I've used on my ER-5!

[@dirtygarageguy]

Mariusmssj M The first filter I ever bought was a Hiflo, never done me wrong, but haven't used others so can't really comment. From what your saying I hit the nail on the head

[@rosenangelov8352]

Nice videos man! I have Er-5 2003 and I am looking forward to see the progress on yours. I would be really happy if you decide to remove rust and paint exhaust collector pipes and rear shocks, because mine are in same condition... Go on!! Best Regards

[@dirtygarageguy]

Rosen Angelov Thanks for the comment. The exhaust will be replaced with a homebuilt stainless exhaust and the shock springs are going to be removed, cleaned and sprayed. Will probably show a little on cleaning the exhaust but won't do the whole thing due to the new upgrade project. Thanks again - matt

[@paulbudford]

Good news the exhaust studs came out. Those can be a real pig of a job once seized up.

[@dirtygarageguy]

Paul Ford No kidding, three of the studs came out and 1 of the acorn nuts came off. Either way they came out. - thanks for the comment - matt

[@riskromer9773]

Aye, got a vulcan 500 ltd and the exhaust bracket is a 2 piece. WHen I took it off both fell as I unscrewed them and now I don't know how to put them back on hahaha. any ideas?

[@dirtygarageguy]

Part listing from OEM parts suppliers

[@a4266]

Sweet, another video! Always looking forward to them. Are you going to be continuing the CX500 enguire rebuild at all? I found your channel due to that. I've got a triked cx500ec that I'm slowly bimbling through on my own.. Never done much on any vehicles other then regular servicing before I got it. So those videos and this series are teaching me loads!

[@dirtygarageguy]

Rigal Cheers for the comment dude. Yes the CX500 is still ongoing. Moving workshop so everything apart from the ER-5 is on hold, but the engine will be fully recon'd. Its killing me all this waiting. Sounds like you have your hands full, did you weld up the frame yourself or did you buy it as a trike? - thanks again - matt

[@a4266]

Pony Power Hi Matt, glad to hear that it's still in the works and I hope that the move to the new workshop goes smoothly! I got the trike from the widow of a friend and the frame had already been done, though not finished as he had planned to put in a bench seat. He had been working on sorting it out, but bought a harley and lost interest in it. I'm currently doing up my garage right now and doing little bits on the trike as I go along. So far I've fixed a few broken wires on the wiring harness, cleaned out the carbs and put them back in. Also rebuilt the starter motor and cleaned it out as it had seized. Still got a long way to go as I need to get the wiring back in (bit scared of wiring and electrics) and the starter motor too. Once I can get the trike started, it's got to be stripped again, cleaned and then I'll repaint the frame and other bits and all put back together. Then, I'll work on the bench seat so I can cart some of kids around with me. REgards, Alex.

[@steveburden1801]

Have been told a few times by lets just say more mature mechanics , that draining the oil cold over a couple of days is better as the crap will have gathered at the bottom. Obviously you need the time. Have you heard this before?

[@dirtygarageguy]

Steve Burden Yeah, also a good idea to use an oil flush but for this its back to the back yard stuff, but a good point. - matt

[@alexestefanesturbo]

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