1986 ex500 throttle problem (rebuilt carb) - Wrist Twisters
 
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post #1 of 34 Old 05-08-2014, 07:23 AM Thread Starter
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1986 ex500 throttle problem (rebuilt carb)

I have a 1986 ninja ex500
The carbs have been rebuilt
Jets have been checked multiple times
But the throttle stalls the bike after about 1/4 to 1/2 throttle given
Can't be ridden.

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post #2 of 34 Old 05-08-2014, 07:43 AM
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Quote:
Originally Posted by xecieon View Post
I have a 1986 ninja ex500
The carbs have been rebuilt
Jets have been checked multiple times
But the throttle stalls the bike after about 1/4 to 1/2 throttle given
Can't be ridden.
Have you checked for fuel supply issues? clogged filter? clogged petcock? bad vacuum (if it's a vacuum operated petcock)

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post #3 of 34 Old 05-08-2014, 08:05 AM Thread Starter
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Yes nothing is clogged.

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post #4 of 34 Old 05-08-2014, 10:09 AM
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What air filter are you using?

Stock airbox or is this a stage III jet kit?

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post #5 of 34 Old 05-08-2014, 09:58 PM
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Are the vacuum actuated carb sliders opening? What shape are the diaphragms in?
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post #6 of 34 Old 05-09-2014, 01:54 PM Thread Starter
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Stock airbox. Everything on the carb seems to be functioning properly with stock parts.

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post #7 of 34 Old 05-09-2014, 02:03 PM
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Stock air filter? Are you positive? I've seen aftermarket air filters cause quite a few problems like this.

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post #8 of 34 Old 05-09-2014, 02:29 PM
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Did it run before the carb rebuild? Is the bike new to you, or have you had it a while? Main reason I ask is in making sure the jets haven't been sized improperly.

Or fuel supply issue, as I think someone else mentioned.

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post #9 of 34 Old 05-09-2014, 03:17 PM
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Diaphragm slides are sticking it sounds like. Did you lube the slides at all while reassembling? If so, with something fuel resistant (oil is not resistant)? If you didn't lube the slides, use some automatic transmission fluid.

Could also be a vacuum issue of its not the air filter.

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post #10 of 34 Old 05-15-2014, 08:04 AM Thread Starter
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It was a project someone else sold me because they didn't have time to finish. The throttle problem went away. I guess it just needed to be ran. Now I'm adjusting the idle seems to be idling high.

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post #11 of 34 Old 05-15-2014, 08:09 AM Thread Starter
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post #12 of 34 Old 05-15-2014, 08:35 PM
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The only problem I had with my ex500 was it liked to eat starter clutches. You might want to have a spare so you can switch 'em out in a jiffy.
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post #13 of 34 Old 05-16-2014, 04:29 PM Thread Starter
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I have a full parts bike with a ton of other extra parts.

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post #14 of 34 Old 05-16-2014, 08:44 PM
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were the orings and other rubber bits replaced? New needle?

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post #15 of 34 Old 05-16-2014, 08:48 PM Thread Starter
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All the parts on the carbs were replaced. I checked everything myself

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post #16 of 34 Old 05-17-2014, 08:37 AM
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Were you able to sync the carbs? Will be hard to get the idle right if they are too far out of sync.

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post #17 of 34 Old 05-17-2014, 08:42 AM
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So if you're sure you have the fuel system sorted out, I'd swap out the ignitor box. Maybe rev limiter or spark advance gone awry. 28 years is a long time for a piece of electronics to live.
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post #18 of 34 Old 05-17-2014, 03:30 PM Thread Starter
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It has a high idle l, the clutch is slightly engaged, and white smoke sometimes comes out of the tailpipe. The exhaust also gets hot. Sounds rich atm but the fuel adjustment screws are only at 3/4 turns. Idk if I should turn them down

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post #19 of 34 Old 05-17-2014, 08:05 PM
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Quote:
Originally Posted by xecieon View Post
It has a high idle l, the clutch is slightly engaged, and white smoke sometimes comes out of the tailpipe. The exhaust also gets hot. Sounds rich atm but the fuel adjustment screws are only at 3/4 turns. Idk if I should turn them down
Hot headers is a sign the mixture is too lean. Are you running aftermarket pipes / air filter? If so, have the main jets been replaced with larger ones. If not, are the main jets smaller than oem? I don't know but jacking up the needles with too many washers might cause high idle.
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post #20 of 34 Old 05-17-2014, 09:57 PM Thread Starter
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It's all stock. So that sounds more lean? Why would it idle so high?

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post #21 of 34 Old 05-18-2014, 05:21 AM
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Quote:
Originally Posted by xecieon View Post
It's all stock. So that sounds more lean? Why would it idle so high?
High idle / hot exhaust could also mean manifold vacuum leak. Do those carbs have vacuum nipples on the back just above the spigots? I seem to recall having to plug those up.
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post #22 of 34 Old 05-18-2014, 05:29 PM Thread Starter
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They are plugged up. I'll spray some carb cleaner around to check it out

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post #23 of 34 Old 05-21-2014, 12:47 PM Thread Starter
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It was the dawn air adjustment screw.... idle is back to normal. Still has a bog. Going to sync it better today see what happens.

Kinda of out off topic. If I changed the muffler. What would I have to do to this bike?

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post #24 of 34 Old 05-22-2014, 09:12 AM Thread Starter
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post #25 of 34 Old 05-22-2014, 10:03 AM
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Did I miss something??? That is not an EX500, that is a Ninja 600R

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post #26 of 34 Old 05-22-2014, 10:08 AM Thread Starter
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Wow... it's registered as ex500

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post #27 of 34 Old 05-22-2014, 01:12 PM
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Quote:
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Wow... it's registered as ex500
Sometime in the 90's that bike was re-numbered 500R. Mine was a '91 ex500 though. This is what I did with it.






That thing would scream @ 10,000rpm all day long.
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post #28 of 34 Old 05-22-2014, 01:19 PM
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Quote:
Originally Posted by xecieon View Post
If I changed the muffler. What would I have to do to this bike?
Generally, any time you change the way a carbureted engine breathes by opening up either the intake or exhaust side or both you will need to re-jet to prevent the engine from running lean.
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post #29 of 34 Old 06-11-2014, 11:02 AM Thread Starter
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I don't want to start a new thread to ask this but the bike runs and rides now. Still needs minor adjustments to be safe but the major problem now is the front brakes. It has no air in the line but no pressure even if I pump the brake for hours. So I gotta ask what a certain part is
Attached Images
File Type: png ForumRunner_20140611_110220.png (242.7 KB, 11 views)

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post #30 of 34 Old 06-11-2014, 11:43 AM
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Looks like a remote adjustment for the front fork.

Nothing to do with brakes, that's suspension adjustment.

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post #31 of 34 Old 06-15-2014, 07:45 PM Thread Starter
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There is a line connecting directly to the brake line

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post #32 of 34 Old 06-16-2014, 05:43 AM
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It could be one of those anti-dive units that were around years ago.

Spoiler:

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post #33 of 34 Old 06-18-2014, 09:08 PM Thread Starter
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It is one of the anti dive units. Wasn't that repaved the caliper and it fixed the problem

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post #34 of 34 Old 06-18-2014, 09:09 PM Thread Starter
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Only thing that needs to be done on this thing is carb sync but my sync is broken so I'm just going to have a shop do it. Oh and registration )

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