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Discussion Starter · #1 ·
I am swapping a Gen2 engine into my Gen1 frame. While I know that this has been done many times by just modifying the flywheel my swap will be slightly different. As of 2011.02.10 this is a work in progress but my expectation is to have the bike completely swapped over by the start of the 2011 riding season.

My intentions are to not modify the Gen2 engine at all. Obviously that means using a complete Gen2 wiring harness. I am also intent on maintaining the Gen1 handlebar switches as well as the Gen1 speedo. In addition I will be mounting a Works Performance rear shock and rebuilding the front forks with new springs.

I know that there will need to be some wire harness pin swaps as well as other changes and I hope to document them all here in one place for future reference.

First step was to remove all the body panels and engine connections:


Old, Gen1 engine, out (and up for grabs [for free]: http://www.ex-500.com/index.php/topic,29776.0.html.
See my other "How To" if you need help removing the engine from your EX/500r: http://www.ex-500.com/index.php/topic,19893.0.html


New (to me) Gen2 engine mounted:
 

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Discussion Starter · #3 ·
Finally got some time to swap in the Gen2 ignition switch and it fit perfect! I was worried that it wouldn't because the shape is slightly different.





In addition to the ignition I changed out all o the other locks so that they would all open with the same key. The helmet locks of a Gen2 are the same as the Gen1s but the seat lock is not. In addition to the arms being different (as seen in the picture below) the locks are mounted differently on the Gen2 than the Gen1. On the Gen1 the two mounting holes on the Gen1 lock are threaded. Luckily Kawasaki used the exact same key cylinders on both. All I needed to do was to swap out the cylinders from the Gen2 lock into the Gen1 seat lock mount.

 

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Discussion Starter · #4 ·
I am coming to find out that not only are there differences between the Gen 1 and Gen 2, but there are differences between the earlier Gen 2 and later Gen 2. I was able to compare my 87 Gen 1, an 04 Gen 2, and an 09 Gen 2. Some of the Gen 2/Gen 2.5 differences are:

Turn signal relay
Side stand switch

Early model Gen 2's use the same version as the Gen 1. I will post pics when I get the parts.
 

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Discussion Starter · #5 ·
Good news! Today I was able to start up the bike. I verified that all gauges and lights on the cluster work. Still need to put some more pieces back on before it will be finished.
 

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you could have fitted gen 2 engine to your bike and still used gen 1 wireing the only mod you would have to off done is used gen 1 magnetto coils and gen2 magnetto you would have to grind a little bit off magnetto.job done. if you want to know what to grint look it up on this site fog will give you measurments it easy
 

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Discussion Starter · #10 ·
moocatdog said:
you could have fitted gen 2 engine to your bike and still used gen 1 wireing the only mod you would have to off done is used gen 1 magnetto coils and gen2 magnetto you would have to grind a little bit off magnetto.job done. if you want to know what to grint look it up on this site fog will give you measurments it easy
Yes, I know. But:

My intentions are to not modify the Gen2 engine at all
And while I appreciate your input I never wanted to make it sound like what I was planning on doing was ever up for discussion. I am going to go through the swap using an unmodified Gen2 engine and a full Gen2 wiring harness; that is a certainty. I just wanted to document the process here for the benefit, if any exists, of others with similar aspirations as I.

I don't mind doing things simply because I can even if there is an easier way.

Two roads diverged in a wood, and I—
I took the one less traveled by,
And that has made all the difference
 

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ok but gen one switches wont work well they will but you will have to change pin positions in 4 way connector and the speedo clocks,wireing wont work on gen 2 wireing.also gen 1 and gen 2 iginitions are not compatible.hope your project goes well these bikes r great
 

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Discussion Starter · #13 ·
moocatdog said:
ok but gen one switches wont work well they will but you will have to change pin positions in 4 way connector and the speedo clocks,wireing wont work on gen 2 wireing.also gen 1 and gen 2 iginitions are not compatible.hope your project goes well these bikes r great
Thanks! I'm anticipating some wiring modifications in the controls (I really like the look of the Gen1 switches) as well as probably having to swap in a Gen2 ignition switch.

I'm also anxious to see what will be involved with getting the Gen1 cluster to work with Gen2 harness.
 

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Discussion Starter · #14 ·
Bike is all done. Everything is working as it should and the Delkevic exhaust system looks and sounds fantastic. I will post pics as soon as I get the belly pan back on.
 

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Discussion Starter · #16 ·
I'm sure you're right but for me the build was definitely a learning experience and a very fulfilling project. And other than some pinout changes and CDI module mounting nothing needed to be modified.
 

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Hi, im currently putting in a gen 2 engine (1997) and a gen 2 wiring harness with cdi etc, what other changes do I need to do? your explanation is very good but it does not seem complete, any more information would be great so I know fully what changes need to be done, im happy at changing wiring and connector blocks etc.
 

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Discussion Starter · #18 ·
Chaostrooper said:
Hi, im currently putting in a gen 2 engine (1997) and a gen 2 wiring harness with cdi etc, what other changes do I need to do? your explanation is very good but it does not seem complete, any more information would be great so I know fully what changes need to be done, im happy at changing wiring and connector blocks etc.
You're right. Looks like I didn't complete the how to.

One of the things that is not listed is the tachometer. I had to swap over one from a Gen 2 cluster. It wasn't hard at all actually. There were also some pins that needed to be swapped on the cluster. I should have the diagrams somewhere, just have to find them.

Are you keeping the Gen 1 controls? I did and I think I just needed a couple pins changed over.

Other than that it was just the ignition and seat lock.
 

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FYI, there are at least a couple small differences between the '94-'97 and '98-'09 Gen2's. The early ones had a 3-prong flasher relay and the hazard switch. I was able to do a direct swap of a '97 left control onto my '09 to add the hazard flasher switch (it just bridges both blinker contacts at once), but there was previously some confusion about the two different flasher units.
 

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I'm hoping to keep the gen 1 controls and clocks and ignition but modify them as needed, as I said I am comfortable with rewiring and soldering etc as I am a bike mechanic in training, if I can get the knowledge to modify these and anything else needed I am more than happy to take pictures and post them etc to help others. As part of my bike repair shop i am looking to specialise in gpz 500s so I am looking to gain all the knowledge about them I can.
 
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