Engine swap compatability.

joekool4 · Aug 25, 2013

Ive got a 91 ex500, a friend of mine bought for me to restore for him. Rather than spend the time and money to rebuild and modify the 1st gen engine (even though it is still an option), I am thinking about swapping for a 2nd gen engine entirely to make the bike ride-able then rebuild the old engine and sell it or keep it for parts. From what I understand that would be any EX500 or vulcan500 94 and newer. will it bold right up? or would I have to modify the frame or wiring? Thanks guys.

joekool4 · Aug 26, 2013

Main reason im asking is because Vulcan engines are cheaper.

VICIOINA · Aug 26, 2013

I believe the size is identical, My nephew has one and it looks the same as mine. I heard that they are tuned different or maybe the trans is geared different. I dont really remember which it is.

joekool4 · Aug 26, 2013

I have been looking almost all day, the search on here wasn't working and I must have read 100 pages worth of stuff with no definite answer. until this

"I did a little research on this several years ago and found the following differences between the EX500 and EN500 engines:
Cylinder head
Carbs
Camshafts & rocker arms
Pistons
Ignition box
From the wrist pins down the engines are identical. Also the valves & springs are the same as well as the transmission parts."
So it would work but they're tuned differently, However, since I have the 1st gen engine that's in the bike, I should be able to just transplant the top end.

VICIOINA · Aug 26, 2013

joekool4 said:
I have been looking almost all day, the search on here wasn't working and I must have read 100 pages worth of stuff with no definite answer. until this

"I did a little research on this several years ago and found the following differences between the EX500 and EN500 engines:
Cylinder head
Carbs
Camshafts & rocker arms
Pistons
Ignition box
From the wrist pins down the engines are identical. Also the valves & springs are the same as well as the transmission parts."
So it would work but they're tuned differently, However, since I have the 1st gen engine that's in the bike, I should be able to just transplant the top end.

I have ridden 2 VN's and they are not lacking in power, they are actually fun to ride, transplant the whole thing as is and if needed you can do the changes later.

rv93 · Aug 26, 2013

those engines will fit without modification. if you swap in a vulcan engine, id recommend going with the carbs that came with it. theyre 2mm smaller, and im not sure how the vulcan engine would run with the ninja carbs (carbs on the ninja are a bit big as it is). but as far as riding with the vulcan engine, it probably suits the character of the bike better. on a track, the ninja engine is better, but the vulcan engine makes more torque at lower revs (i think the ninja catches up above 8k rpm), which is more useable

joekool4 · Aug 26, 2013

That's good to hear. I the engine im looking to buy is about 100 cheaper than any of the ex engines I've found but it doesn't come with carbs, which is why I was thinking about the top and swap along with the clutch and a few other parts that are needed. Basically cannibalizing the ex that's in the bike. But if the carbs will work even with re jetting, just to make the bike ride able for now. Kid needs a way to get to work after he comes home from boot camp.

rv93 · Aug 26, 2013

i dont believe they would need to be re jetted. im not sure if the boots between the head and carbs would fit, but if they do, you can just run the vulcan engine with the ninja carbs. itll work. it might not run quite the way its supposed to, but if you just need it to ride, it should work

joekool4 · Aug 27, 2013

ooh, ok. so with the ex carb boots it should fit. And apparently the Vulcan guys have been doing the opposite for the higher performance.

VICIOINA · Aug 27, 2013

joekool4 said:
ooh, ok. so with the ex carb boots it should fit. And apparently the Vulcan guys have been doing the opposite for the higher performance.

Thats silly since that bike is hard to ride past 80 because of the seating position! Wind beats the crap out of you.

Engine swap compatability.

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