EX500 problems should I do something about the catalytic converter?

L

leitlang

Well-known member
First post! So I got my first bike last season - 1998 EX500, 49k - and it refused to start already before the last season was over. I started taking it apart with the intention of working on everything possible before this season. When the weather was already "riding permitting" and I hadn't yet gotten her running I decided to get help, my buddy's buddy worked for a mechanic for a while, so I paid him to see what he could do. The main problem seemed to be the petcock which he fixed. Carbs still havent been cleaned incidentally. Anyway when he finished, it was running though often hard to start and it feels like there's less power than there used to be, and the bike is sometimes reluctant to rev too high; there's also popping noise and some gurgling I guess comin from the left tailpipe. When I mentioned to him after my test ride before he left he said it may have something to do with the catalytic converter. .
(incidentally, to make the throttle less sticky, he disconnected the 2nd throttle cable (not the "open throttle" one) from the carburetor. Just mentioning in case it's relevant).
Anyone have any ideas or advice? Cheers
 
Once upon a time i had an EX500.

I had a problem where one coil would intermittently cut out and the symptoms were similar to what you describe. There are two small gauge wires that attach to the coil, disconnect them and clean the terminals. Apply some dielectric grease then re-attach the wires.

Get some new throttle cables too.
 
1) Find a new mechanic, the one you've got doesn't know what he is talking about. EX500s don't have a cat, which is pretty easy to see. The fact that he said it did is scary.
2) When you find this new and improved mechanic he or she will want to clean the carbs real good... and replace the throttle cable.
 
ughh, your buddy's buddy is a hack; makes me sick....

clean your carburaters and take it from there. that should improve things.

cables need to be lubricated. replace them if you can't get the cable running smoothly within the sheath.
 
koalaKid said:
ughh, your buddy's buddy is a hack; makes me sick....

clean your carburaters and take it from there. that should improve things.

cables need to be lubricated. replace them if you can't get the cable running smoothly within the sheath.
Click to expand...

Yup, clean the carbs and lube the cables. EX500s don't have a cat.

Hopefully fyrebug sees this thread, he can give you better advice as he owns a EX500 too.
 
caboose483 said:
Once upon a time i had an EX500.

I had a problem where one coil would intermittently cut out and the symptoms were similar to what you describe. There are two small gauge wires that attach to the coil, disconnect them and clean the terminals. Apply some dielectric grease then re-attach the wires.

Get some new throttle cables too.
Click to expand...

Do you think that's necessary (new cables)? It sounds complicated and possibly expensive but if I need em I need em. . And why are there two throttle cables at all? I currently still only have one attached.
As for the "coil" "gauge wires" "terminals" I kinda never heard of them, what/where are they?
Thank you
 
bitzz said:
1) Find a new mechanic, the one you've got doesn't know what he is talking about. EX500s don't have a cat, which is pretty easy to see. The fact that he said it did is scary.
2) When you find this new and improved mechanic he or she will want to clean the carbs real good... and replace the throttle cable.
Click to expand...

I cleaned the carbs, and I'm still having the same issue - could it relate to the throttle cables? And as for the mechanic, if it sounds like it'll be necessary let me know and I guess I'll take it in but I was trying to avoid that.
So the issue now is kinda: I start the bike, normally settles into a consistent rev level when idling, yesterday fluctuating but still, when I ride I have less power, sometimes when I open the throttle at a certain point, say 5000rpm, it makes like a deep popping/coughing sound or something; then randomly something "catches", and I accelerate nicely. Incidentally, the longer I'm riding it it seems the less problems I get..
Cheers!
 
koalaKid said:
ughh, your buddy's buddy is a hack; makes me sick....

clean your carburaters and take it from there. that should improve things.

cables need to be lubricated. replace them if you can't get the cable running smoothly within the sheath.
Click to expand...

"The sheath" meaning the thing next the grips? And is that the only part to lubricate (I'm guessing with WD-40)?

thanks boss
 
leitlang said:
"The sheath" meaning the thing next the grips? And is that the only part to lubricate (I'm guessing with WD-40)?

thanks boss
Click to expand...

The sheath is the harder plastic that goes around the cabling. The cable itself should move in and out with little resistance. I don't think WD-40 is the best, according to my owners manual, the throttle cable can be lubricated with oil. You can always pop into your local dealer and I am sure they can sell you some sort of specialized product
 
There are three things you need to check. Fuel,air and spark. You mention you cleaned the carbs. If by that you mean you ran carb cleaner thru them and you still having problems you should probably remove, disassemble and rebuild them.
http://www.ex-500.com/wiki/index.php/Carburetor_Maintenance

Air is straightforward: Check your airfilter and airbox. Clean or replace the airfilter.

Remove the spark plugs and check that you are getting good spark. If not, you may need to replace the plugs and/or wires or coils. Coils are expensive so start with plugs and wires.
http://www.ex-500.com/wiki/index.php/Spark_Plug_Installation_and_Maintenance

The other thing that can affect performance is valve adjustment. These need to be checked and adjusted every 10 to 12,000 km. The tendency of the ex500 is for the exhaust valves to tighten up. This is more complicated than the previous maintenance but it can be done if you have the tools and patience.
http://www.ex-500.com/wiki/index.php/Valve_clearance_adjustment

As you can see, ex-500.com is a great resource. In addition, if you going to do the work yourself, I would suggest buying a Haynes manual. I bought a 1999 ex500 last year with 20k on it and had similar problems to what you described. I ended up buying the manual, rebuilding the carbs, replacing the plugs and wires, installing a fuel filter, putting in a K&N air filter and doing the valve adjustment. It now runs great! If you're not comfortable doing all this yourself, find a reputable mechanic. Ted, at RoseyToes has a good reputation and reasonable rates.
 
The second throttle cable normally pulls the throttle closed if the springs don't. You really do want it in place. New Cables are not all that expensive or hard to run if your cables are frayed or gunked up enough that they stick.

As stated above I would do the basic maintenance to get the major things back in good shape.
-replace the spark plugs
-check and clean/replace the air filter
-check and adjust the valves
-dissemble and clean the carbs

See how it runs after that. It its still having issues the check the coils and plug wires.

None of the basic stuff is really hard. If you are comfortable turning a wrench, I would suggest getting a service manual and have at it.
 
Ontario Cycle Salvage (if it still exists) is where I got replacement throttle cables for my old CB550 when I needed them. Just bring your old cable with you to make sure you get the exact same thing. When I went, I picked the cables out of a huge bin haha.
 
leitlang said:
Do you think that's necessary (new cables)? It sounds complicated and possibly expensive but if I need em I need em. . And why are there two throttle cables at all? I currently still only have one attached.
As for the "coil" "gauge wires" "terminals" I kinda never heard of them, what/where are they?
Thank you
Click to expand...

Coils are what generate the high voltage current to the spark plugs. Your EX500 has two coils.

They are under the tank mounted to the inside of the frame. There is a big wire that comes out and goes to the spark plug, and there are two small wires that come from the main wiring harness and attach to each coil. Remove the two small wires from each coil then clean the electrical contacts to make sure there is a good connection. Fine grit sand paper works for cleaning the contacts. Then apply some dielectric grease to each contact (this helps keep moisture out and prevents corrosion) and re-attach the small wires.

Do that for both coils. Hopefully that helps.

Yes, you really should have two throttle cables.

Go to a bike shop and ask if Motion Pro offers replacement cables for your bike. They make good stuff and are a lot cheaper than OEM.
 
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