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How to adjust a KLE500 engine to a VULCAN EN500 LTD

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BOAZ
L Plate Warrior



Joined: 13 May 2010
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PostPosted: 22:26 - 13 May 2010    Post subject: How to adjust a KLE500 engine to a VULCAN EN500 LTD Reply with quote
hallo
I'm trying to learn what is the difference between my Vulcan EN500 engine and a KLE or ER5
the thing is i want to replace the old EN's engine with a full of live like new engine from a crashed KLE.

i hope i can do most of the work my self and i will thank for any information that you share with me

my vulcan500 is 1997
engine from 2005 kle
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hmmmnz
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Joined: 22 Aug 2006
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PostPosted: 07:39 - 14 May 2010    Post subject: Reply with quote
well the electrical system looks almost the same, which is a bonus,
normally thats the thing thats different between different model bikes that use the same engine,
the bore and stroke are the same, and there is only 3/1000th of a mm difference in cam lobe heights, so for all intensive purposes the engines are the same, it should be almost a straight swap...

famous last words Very Happy you won't know any differences untill you attempt the swap.

good luck
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BOAZ
L Plate Warrior



Joined: 13 May 2010
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PostPosted: 09:03 - 14 May 2010    Post subject: Reply with quote
thanks man.
that is encouraging
i am giving my self the weekend to learn about camshafts
being a beginner mechanic,i don't know what adjustments it will take ,for the cam to fit.
i assume that the :"there is only 3/1000th of a mm difference in cam lobe heights" needs adjustment,
if so maybe you can give me a direction of thinking or a link to where i can learn the basics on the above, that would be grate.
thanks allot
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Frost
World Chat Champion



Joined: 26 May 2004
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PostPosted: 09:13 - 14 May 2010    Post subject: Reply with quote
Cam lobes are in the top of the engine and won't effect to fitting of the engine in any way. If you don't know what cam lobe heights are, should you really be attempting an engine swap? I'm not saying that you can't do it or even that you shouldn't, but maybe get someone with some experience to help?
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BOAZ
L Plate Warrior



Joined: 13 May 2010
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PostPosted: 09:54 - 14 May 2010    Post subject: Reply with quote
thanks for your reply.
i will not attempt the swap until i understand mouch more.
if i find some experienced friend to help ill be happy.
that is a good advice
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hmmmnz
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Joined: 22 Aug 2006
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PostPosted: 10:04 - 14 May 2010    Post subject: Reply with quote
what i was saying is the the cam lobes (the bits that push open the valves) were so close to being exactly the same, that 3/1000th of a mm is nothing, you could barely measure that difference, even with damn good tools,

i would just attemp the swap,
pull your old engine out, and pull the engine from the kle, and have a measure of the engine mount points,
and then if its close enough to being the same, chuck the kle engine in your frame,
connect up the electrics and carbs, and go for gold Very Happy Thumbs Up

doing it, you will learn far more than just reading about it.
may this be a first step, in a fun filled motorbike tinkering future,

get to it Thumbs Up
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stinkwheel
Bovine Proctologist



Joined: 12 Jul 2004
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PostPosted: 11:40 - 14 May 2010    Post subject: Reply with quote
hmmmnz wrote:
well the electrical system looks almost the same, which is a bonus,
normally thats the thing thats different between different model bikes that use the same engine,


Same number of pickup coils? They did two sorts, One with one, one with two.

I've certainly put a GPZ engine in a KLE. The EX500 motors seem pretty universal in fit.

I did run into problems with the airbox. The GPZ version had a much more advanced airbox design (it had a radically different cam profile too) and wouldn't run properly with the KLE one. I landed up with a compromise using the KLE jetting in the GPZ carbs. It still doesn't run quite right because I used the GPZ CDI unit which has a different advance curve too.

So, what's that in simple speak?

The engines are almost certainly the same dimensions and should fit in the frame. There can be subtle differences in the ignition timing and carburettion. I'd suggest using the bikes original carbs and CDI unit if possible which will be set up for the airbox design on that bike.

If you're going to use the donor bikes carbs and CDI, I'd try to swap the airbox too, but you can land up with headaches.

There seem to be two sorts of engines. Silver ones and black ones. The silver ones are in a lower state of tune. If you're changing silver to silver, you're pretty much ok. If you're mixing colours, you can run into niggly problems.

Oh, another thing to check. Not all EX500 motors have the gearbox the same way round. Look at which way the gearbox shaft moves. Someone off here put an ER5 motor in a KLE and the gearbox worked upside down. Not necessarily a problem, it still works, just racing change.
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Frost
World Chat Champion



Joined: 26 May 2004
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PostPosted: 13:20 - 14 May 2010    Post subject: Reply with quote
So if i paint my engine red, will it go faster? What kind of a horse power increase can i expect?
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hmmmnz
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Joined: 22 Aug 2006
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PostPosted: 13:34 - 14 May 2010    Post subject: Reply with quote
DaFrostyOne wrote:
So if i paint my engine red, will it go faster? What kind of a horse power increase can i expect?


no red is the slowest colour,
you lose 2hp minimum Very Happy
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chris-red
Have you considered a TDM?



Joined: 21 Sep 2005
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PostPosted: 13:58 - 14 May 2010    Post subject: Reply with quote
hmmmnz wrote:
DaFrostyOne wrote:
So if i paint my engine red, will it go faster? What kind of a horse power increase can i expect?


no red is the slowest colour,
you lose 2hp minimum Very Happy


Every knows blue with a pink powerband (yellow for low revs) is the fastest colours
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DrDonnyBrago
World Chat Champion



Joined: 03 Jan 2010
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PostPosted: 16:23 - 14 May 2010    Post subject: Reply with quote
chris-red wrote:

Every knows blue with a pink powerband (yellow for low revs) is the fastest colours


That aint true bruv my platernum powerband is the shiz, 95mph on a flat with my rs50 innit.
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BOAZ
L Plate Warrior



Joined: 13 May 2010
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PostPosted: 17:53 - 14 May 2010    Post subject: Reply with quote
thanks for the colorful welcome guy's
i by the way am going to paint my en black, just got my sandblasting pistol.
have a grate weekend
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Frost
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Joined: 26 May 2004
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PostPosted: 19:04 - 14 May 2010    Post subject: Reply with quote
https://familyrights.us/images/cheese-grater-slide_large.jpg
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