Kawasaki ER5/KLE/EX500 - Episode 71 - Starter motor and stuff

In this episode we attach the oil feed for the head, starter motor and chain gubbins.

[@memybikeni9931]

Love the black/orange scheme. Awesome.

[@trevinkel]

Good channel, keep it up! Just bought a 2002 ER5. Will go back to these videos for sure!

[@dirtygarageguy]

Thnaks for the comment dude - matt

[@TheMund101]

10/10 for attention to detail with tools colour-matched to the bikes paint scheme :P M

[@TheMund101]

Where you were talking about the powdercoating plugs, do you have your own gun & kit for powdercoating & if so can you recommend one for small-scale/project use that's easily available in the UK? Cheers

[@dirtygarageguy]

I have the eastwood Hotcoat kit and its awesome. I bought it from frosts here - www.frost.co.uk/eastwood-hotcoat-dual-voltage-powder-gun-starter-kit.html

[@TheMund101]

The Workshop Thanks for the reply, Matt - I shall be looking into that :) M

[@CLWoodturning]

Mate...is ep 74 the last one?

[@HerzensburgerYT]

Maybe a weard question but just to make sure. In what way is the starter motor + chain supposed to spin? To the right or the left from the top?

[@onhawaii]

I wonder why they did not put a polyamide bushing that runs free around the part where the starter chain wears on... You can just replace it when worn. And it would reduce to noise it makes too... But then the thing might work to long.

[@KyleHowlett-kr6dg]

did you ever post the airbox mod you mentioned on a video about stopping fuel flowing into the crankcase breather?

[@theblueboy20]

Great video was just wondering what is the size of the flywheel puller is thanks

[@garryclark1117]

Did u ever find out what size it was ?

[@theblueboy20]

@@garryclark1117 I bought a six in one puller can't remember if it was m16 1.5 rh or m18 1.5 rh

[@garryclark1117]

@@theblueboy20 thanks will have a look in to them just can’t seem to fine the size any ware cheers :)

[@theblueboy20]

@@garryclark1117 Kawasaki er5 book states m16/m18/m20/m22 x1.5 special tool. it's m18 x1.5 just went and checked the tool

[@garryclark1117]

@@theblueboy20 brilliant mate thanks for the help

[@kubussek3]

Can I take off the cover, take off the fly wheel without special tool, check the starter chain wear, and assemble all this back without new gasket (if old is good enough?). Flywheel is not in oil right? Or without flywheel holder it's too tricky? I'm curious because I recently bought er-5 and I just want to check everything ;) But maybe I shouldn't if there is nothing wrong with starter?

[@dirtygarageguy]

Good question mate - You'll need a flywheel puller, the threaded rod thing I had. Yes the flywheel is exposed to oil, the sprag clutch and the chain require oil. You could reuse the gasket if it comes off in one piece but its highly unlikely for a bike of this age. If there's nothing wrong then I wouldn't bother to be honest - matt

[@kubussek3]

Thanks!

[@dirtygarageguy]

no worries mate

[@csotanyjoe]

Hello! You did an awesome job! Where can I see the finished motorcycle? Thank you!

[@dirtygarageguy]

I started back on the ER5 todya - video soon

[@theunnamed5775]

I have a kle500 with a dead starter motor. Does the er5 share the same starter motor? Nice vid by the way.

[@peregrine257]

i have not seen you install the cam chain tensioner yet........when i striped my engine, i learnt that my cam chain tensioner cam from a GPZ.....are they safely interchangable or do i need an ER 5 CCT..cheers.

[@dirtygarageguy]

Good question, I don't actually know - check the parts numbers and see if they're the same

[@DoubleYouPee1]

The big starter gear on the crank is only using friction to move the crank?

[@dirtygarageguy]

It has a sprag clutch. Video this weekend - coming soon - lol

[@bilhep]

From the Mag-side, does the engine rotate clockwise?

[@lachlanandferguswearepros4577]

what modification did you do to stop fuel going through the crankcase breather hose ?

[@dirtygarageguy]

Thats for a future episode - matt

[@RidingWithGerdas]

I will need to change sprag clutch soon to my twister, so this stuff is useful mate. You have any advice for changing it or something to have in mind while doing it?

[@dirtygarageguy]

Nothing apart from get OEM gaskets the aftermarket ones are shite.

[@RidingWithGerdas]

The Workshop Sure will. Any tips of removing flywheel without that tool from video?

[@imoner]

Hi! I've got a problem with starting my kawasaki er500. I think the problem is with the starter motor, but can't be sure? Can I send you a video so you will take a look?

[@dirtygarageguy]

Go for it

[@imoner]

@@dirtygarageguy uploaded it. Short, with sound kzbin.info/www/bejne/r6nRmGiups5nhJo

[@mirniygitel1913]

Hello, how to visually determine how much horsepower in Kawasaki is 5, 34 or 50? Kawasaki er 5 twister 98 'year of release! Thank you

[@dirtygarageguy]

sorry dude I don't know what you mean?

[@RidingWithGerdas]

The Workshop I guess he want to know if the bike is restricted or not, there should be mechanical limiter, could be something that limits fuel flow right?

[@stefanvandborg]

Hi first I will say thank you for these great videos dissecting a gpz 500 engine. Nice to know how the bike looks inside. I took a look at my gpz 500 today because while driving all of a sudden it was like it wouldn't take the gas. I noticed the hole on the breather cover (just learned from your video what it was called) is there supposed to be a hose going from that hole? Or is it supposed to be all open like mine? I thought maybe that could be the problem, or maybe my carburators need cleaning. After looking at it for 5 minutes I drove home without any problems. It comes and goes. Kind regards from Denmark

[@seancooling2007]

Can someone please tell me why i can only get to episode 75..I can't see the finished bike ???

[@dirtygarageguy]

Because it's not finished yet - that would explain it.

[@seancooling2007]

@@dirtygarageguy jesus no need to be smart I was interested in seeing more of the bike is all..is 75 the last one put up ?

[@dirtygarageguy]

Not being smart just cocky LOL And just winding you up. But seriously no, the ER5 is still where I left it - other things came up and it wasn't a top priority - but it will be picked up in the future