Ninja EX500 carbs on an XS650?

muks · Feb 28, 2015

Thanks. I've been keeping an eye out for EX500 carbs but struggling to get a hold of any, I have come across some GPZ500 ones though so might go for it. I'm halfway through this thread and it seems like a worthwhile upgrade.

pekka · Feb 28, 2015

I think they are. I have EX500 (or actually ER5) carbs. The jets are apparently different but you need to change them anyway.

pekka

jd750ace · Feb 28, 2015

EX500, ER5, and GpZ500 all have the same basic carbs, although with minor differences in jetting.

Maurice · Mar 2, 2015

wannabridin said:
You have an allen screw that small? And I removed them to fully clean the carbs, which is what I do with any carb that I buy off e-bay. Soda blast everything to remove varnish and road grime and then a full ultrasonic clean in Simple Green Pro-HD (Al safe). Then some index drill bits and carb cleaner through all passages followed by compressed air. Well worth the effort.

If you have some pics of these butterfly shaft screws, please post them up and where you got them, i bet lots of people would benefit. They're tough to remove because they're designed to stay put ones installed. If I went with a regular threaded screw, you'd have to put some blue loctite on it at minimum to keep them from backing out and causing your carbs to stick open or close.

Sorry for posting this late, been real cold here and my garage is not heated. Here are some pics:

Let me know if you need a few. I have not tried on CVK carbs but have used them on others should be the same size.

aldo5468 · Mar 6, 2015

Has anyone found an inline gas filter that can fit in the "hole" between these carbs? I use a small Fastex Visu Filter mounted vertically between my BS34's that have the fuel T centered between them, but the CVK's have their fuel T positioned way over against the left carb, so no room for that. I use a 750 gas tank that has pretty fine screens above its OEM petcocks, so maybe I wouldn't need another "downstream" filter, but if there's a slick solution, I'd go with the extra insurance - these CVK emulsion tubes have damn small holes. :bike:

Uhlaf · Mar 7, 2015

Quick question, what exactly did you guys do to have the stock XS650 throttle cable fit the EX500. I've spent the better part of the winter sourcing the carb and parts and don't want to muck something so simple up so close to ridable weather.

wannabridin · Mar 7, 2015

aldo5468 said:
Has anyone found an inline gas filter that can fit in the "hole" between these carbs? I use a small Fastex Visu Filter mounted vertically between my BS34's that have the fuel T centered between them, but the CVK's have their fuel T positioned way over against the left carb, so no room for that. I use a 750 gas tank that has pretty fine screens above its OEM petcocks, so maybe I wouldn't need another "downstream" filter, but if there's a slick solution, I'd go with the extra insurance - these CVK emulsion tubes have damn small holes.

have you considered running the internal fuel rail filter? it's from a kawakaski. you can't see it, works well.

http://www.ex-500.com/wiki/index.php?title=Fuel_Filter_Installation

56nomad · Mar 8, 2015

Uhlaf said:
Quick question, what exactly did you guys do to have the stock XS650 throttle cable fit the EX500. I've spent the better part of the winter sourcing the carb and parts and don't want to muck something so simple up so close to ridable weather.

Uhlaf,

Check out my post #271 for a very simple way of doing it. It's never been any problem and TBH they don't need the second 'push' cable as per the OEM Kawasaki set-up as the return spring is sufficiently strong enough on it's own. I'm still using this set-up now and intend repeating it on my other XS when it's finished.

For the choke cable check out post #235. Also simple.

Ian

aldo5468 · Mar 8, 2015

wannabridin said:
have you considered running the internal fuel rail filter? it's from a kawakaski. you can't see it, works well.

http://www.ex-500.com/wiki/index.php?title=Fuel_Filter_Installation

Thanks, wannabridin - that's exactly the kind of thing I was asking about.

Uhlaf · Mar 9, 2015

Went out and bought some cable clamps the secure the throttle and a small spool of aircraft cable to loop around the choke. $10 and I like the cable choke.

wannabridin · Mar 9, 2015

Uhlaf said:
Went out and bought some cable clamps the secure the throttle and a small spool of aircraft cable to loop around the choke. $10 and I like the cable choke.

Let's see some pictures of that setup if you dont mind.

FrilandXS · Mar 10, 2015

First of all this thread is amazing.
I currently have to carbs at all,so I'm going with this swap, with air pods and aftermarket exhaust on my stock 650, no rephase just pamco.I got a good deal for a pair of GPZ500 carbs but first I want to provide my jets and needles

I'm looking forwad to order:
Main: 138 and 140
Pilot: 38 and 140
Needle : JJJ PWK28

But since I don't have the carbs yet I don't know which jets on this catalog are the mains and pilots for the Gpz carb

http://www.allensperformance.com/keihinjets.html

So, can someone help me with that?

tonyc · Mar 10, 2015

Even though I love my Vm34', I have to try these carbs. I have set of EX500's 2002 bing delivered Wednesday. I will then order the jets that Mr. Riggs has been using. Stay tuned. Tony C.

56nomad · Mar 11, 2015

FrilandXS said:
But since I don't have the carbs yet I don't know which jets on this catalog are the mains and pilots for the Gpz carb

http://www.allensperformance.com/keihinjets.html

So, can someone help me with that?

Hi Friland,

First of all Allens Performance are good guys and they'll certainly fix you up.

The Mains are 99-101-393-SIZE
The Pilots are N424-25B-SIZE

Replace the word 'SIZE' with the size of jet you require such as 138 and 140 for the Mains and 038 and 040 for the pilots.

Happy to help.

FrilandXS · Mar 11, 2015

Thanks, 56nomad

tonyc · Mar 11, 2015

Well my carbs arrived today in the mail. They look like new. I cannot wait to transform them for my xs650 and hopefully with the same success as everyone else.

tonyc · Mar 11, 2015

Forgot pictures.

ippytattoo · Mar 11, 2015

tony. Those look outstanding. Hopefully they are as clean inside as they are on the outside. Have you ordered your jets yet?

tonyc · Mar 11, 2015

I have not ordered jets. I will go with 38 pilot 138 main and a GJH needle. Will I have to change the needle jet? Ippy where did you order your jets from?

ippytattoo · Mar 11, 2015

I ordered my jets from jetsrus.com and I don't think anyone has had to change the needle jets just the pilot & main jets and the needle itself.

By the way, not to highjack this thread but, how is you clutch treating you these days? I am sure you are starting to rack up the miles on them.

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