[Billyfixit]

I have an 06 ex 500 with a completely locked up engine. I have an opportunity to get a 06 vulcan 500 engine for it on the cheap. I've searched on here and its supposedly interchangable. The problem I noticed from just looking at the engine is that the vulcan shifter is about 8 inches farther away than from the ex engine. The vulcan engines shifter is at the front of the engine where as the ex engines shifter is more towards the back and then goes back even further with the shift rod. So what gives? Can it be swapped? thanks in advance.

 

[yorkie]

hi, as long as you understand the the Vulcan is a lower output engine in comparison to the EX and your happy with that no problem it will go straight in. just use the basic engine, and fit to it all the EX kit and it will be fine.
the gear linkage bit is a red herring as the selector shaft on all engines is the same just junk the Vulcan kit and use the EX linkage and lever.

 

[Billyfixit]

hi, as long as you understand the the Vulcan is a lower output engine in comparison to the EX and your happy with that no problem it will go straight in. just use the basic engine, and fit to it all the EX kit and it will be fine.
the gear linkage bit is a red herring as the selector shaft on all engines is the same just junk the Vulcan kit and use the EX linkage and lever.

So are you saying I just need to use the ex left case and innards? I do know that theres a difference in power. I read that the ex has more power in the high rev range and the vulcan has a bit more torque in the low rpm range. Also I believe the igniter and carbs are different as well? I guess its not really just a plug and play then. Now I'm thinking gasket sets and other parts as well. more $$$$

 

[yorkie]

what I'm saying is if the Vulcan is a 06 it should be a gen 2 motor so same as the basic EX 06.
how hard you make it is up to you. the engine doesn't know whether it's in an EX or a Vulcan put the engines side by side and swap whatever is different (won't be much) you have the parts on the EX already.
if the flywheel and case are used off the EX the igniter wont matter it matches the EX ignition same with carbs yes the Vulcan uses smaller jets (on the Vulcan) but are the same carbs so should work on whatever motor you use.
if your picky change the jets while the carbs are off. apart from that all the extra you need is tube of RTV for gaskets.

or in other words everything that belongs on the EX can be transferred to the Vulcan engine.

 

[Billyfixit]

what I'm saying is if the Vulcan is a 06 it should be a gen 2 motor so same as the basic EX 06.
how hard you make it is up to you. the engine doesn't know whether it's in an EX or a Vulcan put the engines side by side and swap whatever is different (won't be much) you have the parts on the EX already.
if the flywheel and case are used off the EX the igniter wont matter it matches the EX ignition same with carbs yes the Vulcan uses smaller jets (on the Vulcan) but are the same carbs so should work on whatever motor you use.
if your picky change the jets while the carbs are off. apart from that all the extra you need is tube of RTV for gaskets.

or in other words everything that belongs on the EX can be transferred to the Vulcan engine.

Thanks, do you know if the electrical plugs are the same. The reason I'm asking is that I dont want to do alot of parts swapping to make it work. I'ld rather just wait and find an ex motor for it if its too much of a hassle. I'm going to be selling the bike so I dont care alot about its performance. Moreso that it runs and rides good. I have another ex 500 thats perfect so I know how they go down the road.

 

[yorkie]

if it's a gen 2 motor yes. like I said it's as easy or hard as you make it.
someone I know wrecked his engine on a 1990 gen 1. so bought a 98 gen 2 motor to replace it, started at 8am taking the old engine out by 4pm new engine in and running. considering he had to modify the gen 2 fly wheel to gen 1 spec and clean the carbs while doing it. that's about average. fitting another gen 2 engine should be a breeze.

 

[FlipFlop]

2009 2nd Gen ex stator cover next to a 2009 EN500 cover. Hope this helps.

 

[Billyfixit]

Thanks guys,good info. Does anyone know what is involved to move the shifter location from front to rear? i.e. does the flywheel need to be pulled.. etc.. ?

 

[yorkie]

Thanks guys, good info. Does anyone know what is involved to move the shifter location from front to rear? i.e. does the flywheel need to be pulled.. etc.. ?

no it doesn't and this question has been answered already.

the gear linkage bit is a red herring as the selector shaft on all engines is the same just junk the Vulcan kit and use the EX linkage and lever.

 

[FlipFlop]

I have never touched a EN500 Vulcan stock. When you get into it, take lots of pictures and post them up. I bought a EN500 cover with hopes to use it on my 500 and decided to not use it, that is why I have it.

 

[Billyfixit]

no it doesn't and this question has been answered already.

The selector shaft on the en is about 8 inches forward on the en engine compared to the ex. What does "junk the vulcan kit" mean? the sidecase?

 

[Billyfixit]

I have never touched a EN500 Vulcan stock. When you get into it, take lots of pictures and post them up. I bought a EN500 cover with hopes to use it on my 500 and decided to not use it, that is why I have it.

Were you thinking about forward controls with the shifter? I'll take pics if I end up doing this job. Still got a few things in the air like getting the title for it first. thx

 

[yorkie]

The selector shaft on the en is about 8 inches forward on the en engine compared to the ex.

no it isn't, you are getting confused with the selector shaft (that comes out of the gear box) and the idler shaft and linkage that is attached to the lower part of the case. so just swap cases. the idler is then gone all you have left is one on the gearbox that the EX linkage fixes to. inspect the flywheel while the case is off make sure it is the same as the EX (it should be) if not swap the flywheel as well. then the engine will go straight in the EX frame and connect up like the stock one.
note the only other thing you will need to do is swap the belt drive engine sprocket for the EX chain drive sprocket. connect everything up as it is on the EX and you are good to go. it's not that hard your overthinking this too much.