Any ideas?

[Mockey]

I'm looking for an exhaust system (Used but in good nick) for my 1992 Kawasaki EN500. The cheapest quote I've got so far is £270 each side! (But thats new). And as a poor student I can't afford that.

So far I've tried:

Ebay (looking for the parts themselves or someone breaking a bike... no luck so far)

Nightingales of Rugby (Where my bike came from Originally.. gave me the £540 quote!)

West Coast Salvage (Waiting for reply)

Because this is an import bike it is harder to get parts for and new parts are seemingly expensive.

Anyone on here know a good bike breaker or someone that could provide the parts for less than £540!

Cheers
Jack
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04/05- Kawsaki Eliminator 125, 05/06 - Kawasaki EN500, 06/present - Triumph Thunderbird 900

[stinkwheel]

You should be able to get a pattern exhaust system that will fit on. From the style I would suggest trying 'Jama original' or 'Marshall Deeptone' as your first ports of call by way of manufacturers.

It looks exactly like a Jama system on your piccy anyhow.

Google away

EDIT:

Try here, looks like you are listed.

https://www.laserexhausts.com/uk/Main.html
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

[Mockey]

Thats great mate, can you order direct from that site, I can't seem to see how you do?
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04/05- Kawsaki Eliminator 125, 05/06 - Kawasaki EN500, 06/present - Triumph Thunderbird 900

[Mockey]

I've figured out that that from www.performancemotorcycleparts.co.uk I can get LASER downpipes for £99 and JAMA mufflers for about £229. Much better price than £540! Me and my mate could fit them no probs...


If I order the Pipes and the Mufflers will I need anything else in order to fit them? Will I need to weld them together (there called slip on mufflers)

Cheers
Jack
____________________
04/05- Kawsaki Eliminator 125, 05/06 - Kawasaki EN500, 06/present - Triumph Thunderbird 900

[stinkwheel]

You should just need two new exhaust manifold gaskets for under the top of the header pipes (about a quid each) and possibly some assembly paste for where the two parts join (although many will seal well enough without).
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

[Mockey]

Looking at the diagrams of the two parts it seems they might come with them already.

Although I'm no expert so I might be wrong...
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04/05- Kawsaki Eliminator 125, 05/06 - Kawasaki EN500, 06/present - Triumph Thunderbird 900

[dodsi]

Just out of interest what are those EN500's like?

I ride an ER-5 which shares the same engine.

Performance etc?

[Mockey]

I'm not sure if they have the same engine. I know they have the same engine as a Kawasaki GPZ500 (but that might be the same as a ER-5 too!) Well mine is restricted to 33 bhp but derestricted they put out 50 BHP. There obviously a less sporty bike than the ER-5 as the EN500 is a cruiser, but I have found it quite nippy, good acceleration. I would imagine it is like riding an ER-5 but with poorer handling, acceleration and brakes! However I found none of those features to be poor on the bike, though I've never ridden a sportsbike.
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04/05- Kawsaki Eliminator 125, 05/06 - Kawasaki EN500, 06/present - Triumph Thunderbird 900

[stinkwheel]

Looks like the parts should join in an airtight maner. You will still need two exhaust gaskets (they go between the engine and the header pipe, either copper or fibre), I don't see any on the diagram.
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

[Mockey]

Could I just take them off my current exhaust system? Its only the part where the silencer meets the downpipe thats knackered.
____________________
04/05- Kawsaki Eliminator 125, 05/06 - Kawasaki EN500, 06/present - Triumph Thunderbird 900

[stinkwheel]

No, the exhaust gaskets are a use-once then throw away part. They cost a whole British pound each! If you reuse them your system will not seal as tightening them down crushes the gasket into shape.

A traditional one is a ring of hollow copper tube, the tube squashes flat as you tighten down the bolts and seals any little gaps between the engine and the exhaust. If you get leaks here, the bike will pop and bang like a rally car. The engine will also run slightly lean which is not good for it.
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

[Mockey]

Are these standard or are they made differently for different models and how do you fit them?

Sorry for all the questions, just I'm not that mechanically minded... don't worry though my mate is a mechanic
____________________
04/05- Kawsaki Eliminator 125, 05/06 - Kawasaki EN500, 06/present - Triumph Thunderbird 900

[stinkwheel]

It is a loose washer that fits inbetween the engine itself and the exhaust. You need to get one that is the correct diameter so it fits in the hole. Your kawasaki dealer should keep you right if you ask for two exhaust gaskets for an EN500.

Below is a picture taken looking at an engine from where the exhaust usually attaches. You should be able to see the old, squashed, copper gasket in place. You would need to remove this and put a new one in there before clamping down the exhaust on top of it.

They settle a bit too so you would want to re-tighten the nuts after 100 miles or so.

https://faq.f650.com/FAQs/Photos/HGasketValvePhotos/ExhaustSeals3.jpg
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

[instigator]

On a bike that age, just be careful on taking the exhaust bolts off. If they won't budge initially, don't apply more and more force, like myself.

Was just going to recommend laser as well.

[stinkwheel]