"" Important things to remember when swapping engines? - Ex-500.com - The home of the Kawasaki EX500 / Ninja 500R
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post #1 of 11 (permalink) Old 4-18-2017, 5:40 AM Thread Starter
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Important things to remember when swapping engines?

Hey everyone, its me again, guy that ruined his old engine by rushing too fast and not asking for help.
Gonna try to fix that this time around.

I got a new '08 engine for cheap and I'm gonna get it into my '05 frame later this week.

I've already taken the old busted engine out, which i did in just under 2 hours, pretty proud of myself, and had no issues.

I just want to make sure that I don't forget anything this time around, so I have a few questions;

1: What oil brand does everyone recommend, and is the 3.6 quarts the correct amount of oil (engine empty and without oil filter yet)?

2: What coolant does everyone use, and is the 1.8L amount accurate?

3: Does anything need to be done with the carbs before it's ready to run? They were rebuilt less than a year ago and worked perfectly up until engine failure.

Any other useful tips and rules to follow to ensure the swap goes off without a hitch would be greatly appreciated! Thanks a lot!
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post #2 of 11 (permalink) Old 4-18-2017, 5:58 AM
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I use Spectro4 non synthetic 10w40 motor oil. I have almost 90000 miles on my bike, and it does not burn any oil. If the bike is 100% completely dry, it takes 3.4 litres of oil. 3.6 quarts sounds about right, but I haven't done the math. I have been using yamalube coolant for the last few years (ever since Kawasaki stopped making full strength undiluted coolant). Don't know if this is the best coolant, but it seams to have been working fine. 1.8 liters is about right on the capacity. Personally I would think the carbs would be ok, but they are already off anyway, so your call. Edit: On an oil change, and when replacing the filter, it takes 3.0 litres of oil.

2006 Ninja500R Purchased new July 2006, 0 miles. Miles as of January 2017 88652. It is a GO bike, not a SHOW bike.
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Last edited by bpe; 4-18-2017 at 6:01 AM. Reason: Oil change info
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post #3 of 11 (permalink) Old 4-18-2017, 12:34 PM Thread Starter
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How exactly did you get nearly 90k miles out of this bike?? What kind of riding do you do? I am very impressed, and thanks for your insight.
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post #4 of 11 (permalink) Old 4-18-2017, 12:49 PM
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Quote:
Originally Posted by roarbot1 View Post
How exactly did you get nearly 90k miles out of this bike?? What kind of riding do you do? I am very impressed, and thanks for your insight.


His mother rode it for most of those miles

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post #5 of 11 (permalink) Old 4-18-2017, 12:55 PM
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Hmm I can't think of anything else to add. I've done 3 or 4 engine swaps on the EX now and it's nothing too tricky. As far as what type of oil, there's a thread on here many pages long. Lots of people have strong opinions on synthetic vs conventional, what manufacturer, what weight. I use conventional 10w40. As far as putting an exact amount in, just set the bike up level on its center stand and fill until you're between the lines on the oil fill glass.

Same for coolant, just top it off from the rad cap slowly, pinch the flex tubes coming from the head and water pump to get air bubbles out. Fill expansion tank til it's between the lines.

Nothing needs to be done with carbs, I just hang em off the left side of the bike from the throttle cables to get them out of the way when I'm putting an engine in. Just take your time and make sure all the boots are seated correctly, crank case breather pipe, coils & plugs, all that stuff is connected and routed.

When i put new exhaust gaskets in I tighten the stud nuts a half turn or so after a few heat cycles.

Also with three engines that I've had sitting for extended periods of time, I've had to burp the oil system at the filter to get oil flowing. Pay attention to that oil light when you first fire up the replacement engine and if it stays lit, don't let that engine run very long. Good luck.
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post #6 of 11 (permalink) Old 4-18-2017, 3:35 PM
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Quote:
Originally Posted by roarbot1 View Post
How exactly did you get nearly 90k miles out of this bike?? What kind of riding do you do? I am very impressed, and thanks for your insight.
Quote:
Originally Posted by fog View Post
His mother rode it for most of those miles

FOG
My mother didn't actually ride it. But I might be willing to go along with maybe I ride it like a girl. I have only had the rpm's up to about 8000. That will get me 100 mph, if I needed to go faster than that, I probably should have got a faster bike. Other than that, quality oil, frequent oil changes, good maintenance.

2006 Ninja500R Purchased new July 2006, 0 miles. Miles as of January 2017 88652. It is a GO bike, not a SHOW bike.
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post #7 of 11 (permalink) Old 4-20-2017, 8:03 AM Thread Starter
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Alright guys, got the new engine mounted without much trouble, got all the doodads back where they should go, everything tightened down and good. Spark was good, so we put in coolant and oil.

Damn thing still won't fire. No vacuum leaks, nearly a fully charged battery.
The gas in the tank is around 6 months old now, I hadn't thought of that. I'm charging the battery now. If I empty the carb float bowls (whatever the things are on the bottom where you turn the hex and it lets fuel out, if i need to do that) and get some new gas in, along with a fully charged battery, should I be good to go? I really hope so...
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post #8 of 11 (permalink) Old 4-20-2017, 11:31 AM
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Yup. But you should probably test that battery, as you could be charging it all day and if it's weak it won't fire the coils.


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post #9 of 11 (permalink) Old 4-20-2017, 12:35 PM
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I'd suggest draining the gas and getting fresh stuff.
Far as the engine goes, did you check valve clearances? Out of spec valves can make a daily ridden bike hard to start in the morning. It'll make an older motor that hasn't been run in a while damn near impossible. Combine that with old gas, and you'll drain the battery before it fires. I took an EX engine that had sat outside for 12 years without running, adjusted the valves, cleaned some nasty residue off the tops of the intake valves, put fresh oil and coolant in, rebuilt carbs, clean gas and it fired up within 10 seconds. I'd say it might be a combination of valves, old gas and carbs.

Now, you think bpe has high mileage, I've got 116,000 on mine and climbing fast. Granted, it's on engine number 3, but engine number 2 had 70,000 when I pulled it. It was running, but making uncomfortable noises, so it's on the bench being rebuilt. Bpe, however, is still rolling his original engine, so bonus points there .
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post #10 of 11 (permalink) Old 4-20-2017, 12:58 PM Thread Starter
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can valves go out of spec within 1-2 months? I believe that was when the engine was pulled out of a bike that ran fine.

When I get home I'll put some new gas in, drain the bowls, and try it with the battery which finished charging this morning.
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post #11 of 11 (permalink) Old 4-20-2017, 3:21 PM Thread Starter
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I started a new thread in the troubleshooting section, as it is where my trouble lie now, thanks to everyone for their help thus far.
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