Common Problems

## **Common Problems with the Ninja 500R**

This is a list of problems common to our beloved motorcycle. Some of these are ordinary or predictable. e.g. the 1st gen bikes have 16" wheels which makes it hard to find tires for that bike. Others are particular to this bike or otherwise unexpected for a new owner.

### **1st Gen Transmissions**

* *Symptom:* Issues shifting from/to 2nd gear, for first generation EX-500's (87-93).
* *Problem:* 1st generation transmission has reliability problems at high mileage.
* *Solution:* Replace or repair the transmission. Second generation transmissions are exact fit for first generation bikes.

### **Gas Tank Vents**

* *Symptom:* Loss of power at high speeds. Power returns after the bike sits for some time, or you open the gas tank to check gas level.
* *Problem:* Gas tank vent is plugged, and so there is a partial vacuum in the gas tank preventing the petcock from drawing fuel.
* *Solution:* Clear the gas tank vent by blowing compressed air through it. The gas tank vent can be found if you open the gas tank; it is the cone-shaped protrusion on the underside of the lid.

### **Loose Speedometer Cables**

* *Symptom:* Speedometer stops working, speedometer cable is dragging on the ground.
* *Problem:* The speedometer cables on these bikes are notorious about working themselves loose with time and miles.
* *Solution:* Speedometer cable is loose or detached. Reattach and tighten properly. One drop of blue (medium strength) Loc-tite on the threaded collar attachment may keep the problem from reoccurring.

### **No Fuel Filter**

* *Symptom:* Carburetor/fueling issues. Especially common when the bike has sat and the fuel is old. Fuel starvation is occurring.
* *Problem:* This bike does not come stock with a fuel filter. As a result, it is predisposed to a variety of carburetor and fuel line problems which could be prevented by the installation of a fuel filter.
* *Solution:* Install a fuel filter. They cost about $3, and it'll take you 30 minutes tops.

### **Bike only runs on choke or dies when given gas**

* *Symptom:* Bike will only run on choke, dies when you give it gas.
* *Problem:* Pilot circuit is clogged.
* *Solution:* Thoroughly clean pilot jets and passageways.

### **Bike Won't Shift Into First**

* *Symptom:* Bike will not shift down into first gear after hard braking.
* *Problem:* Due to design of transmission, it must be rotating to change gears easily.
* *Solution:* Roll bike forward or backward one or two feet with clutch held in, then retry shifting.

### **Engine Light comes on after dropping the bike**

* *Symptom:* Engine Light stays on.
* *Problem:* Air in the crankcase.
* *Solution:* Loosen the oil filter until oil just begins to leak. Then crank the engine briefly, until oil begins to spurt out. Now tighten the filter back up, and the oil light should remain off. This process is called "burping" the bike. It is commonly necessary after a bike is dropped, which may introduce bubbles to the oil system. This process removes the bubbles. Afterwards, make sure the oil level is still in the window; add oil if necessary to replace that which is lost.

### **Headlight Aiming**

* *Symptom:* Headlight seems aimed down; area illuminated is small and close in front of the bike.
* *Problem:* The headlight on the 500R is almost always aimed too low. It can easily be adjusted to a better level.
* *Solution:* Aim the headlight.

### **Clutch Slippage/ Weak Clutch Springs**

* *Symptom:* When rolling on the throttle, especially at highway speeds, RPMs increase before road speed does; the clutch is slipping.
* *Problem:* The clutch is slipping due to weak clutch springs, which are causing the clutch to not completely engage.
* *Solution:* Replace the worn-out stock clutch springs with some stiffer ones in 20 minutes for about $20!

### **Brake Lights Constantly On or Rear Brakes Lights not working**

* *Symptom:* Brake Lights Constantly On or Rear Brakes not lighting up when pressed.
* *Problem:* The brake spring needs to be adjusted due to a weak spring, which is causing the light to be constantly on or not to come on when the rear brake is applied.
* *Solution:* Turn the mechanism in the plastic thread(It's near the rear brake), to tighten it up against the spring, takes less than 10 seconds!