kle500 gpz500 engine swop

[wildmetal]

have fitted a gpz500 engine in my kle500 . but it wont start any advice on what it could be .

[stinkwheel]

What model GPZ engine?

Did you swap the CDI unit too?

Which carbs did you use?

I have some experience in this matter:
https://i48.photobucket.com/albums/f216/stinkwheel/c920f33e.jpg
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

[wildmetal]

the engine i been told is out of a a reg bike . using standard kle500 carbs and air box . also the kle cdi . i know that the flywheel and pick-ups are different on the gpz engine . i have tryed to get the kle500 rotor off but have busted 2 off the magnets . do you know what size puller i will need to remove the rotor . know any were i can get a cheap replacement ?

[Kickstart]

Hi

You need a puller to get the flywheel off the gpz engine. And the flywheels lose their magnets easily although you shouldn't have been pulling on the flywheel anywhere close to them.

The difference between the early and late gpz ignitions is the number of pickups, which means a different flywheel with different ignition triggers on it. Not sure if the early flywheel cover will locate the late ignition pickup in the correct place.

You say it doesn't start. Does it crank over? Does it spark? Which flywheel / ignition cover and pickups / cdi are you using which are failing to start?

All the best

Keith
____________________
Traxpics, track day and racing photographs - Bimota Forum - Bike performance / thrust graphs for choosing gearing

[stinkwheel]

You are correct to use the KLE carbs though, airbox differences mean it won't run with the GPZ jetting.

The ignition advance curve is different between the KLE and the GPZ. When I did it I used the GPZ CDI.

You have an early model GPZ500 motor there which has a double ignition timing pickup coil and a single trigger on the rotor. The KLE has a single pickup and a double trigger on the rotor.

So how did you connect the GPZ motor to the KLE CDI?

I would suggest getting yourself an early model GPZ IC igniter box and fitting this which will set you back £30-40.

I should be able to help you with how to wire it in because I have manuals for both bikes. Should fit in there with the standard wiring loom, just a case of connecting the correct wire to the correct terminal on the IC igniter.
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

[wildmetal]

the gpz motor still has the rotor on it . i swopped the casing over off the kle hoping that would do it ,but no . you are correct in that the pick-ups are not the same . the gpz has 2 the kle 1 . i do have the other casing off the gpz . could i fit the gpz rotor and casing and then add the gpz cdi

[Kickstart]

Hi

You need the flywheel, cdi and pickups (possibly cover) to match. Problem is any wiring connectors to the loom.

All the best

Keith
____________________
Traxpics, track day and racing photographs - Bimota Forum - Bike performance / thrust graphs for choosing gearing

[stinkwheel]

I've always been of the oppinion that the CDI should go with the engine. Keep all the original internals that went with the GPZ engine and attach them to the GPZ CDI unit.

The main trouble I can see is that the wiring diagrams show 9 wires in a row but the CDI has a multi connector block with 2 rows of pins.

I fucking hate it when they do this.

I'd need a pin layout diagram at best, or at least a picture of a CDI connected up or the connector block that plugs into it so i can see which wire goes to which pin.
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

[wildmetal]

i think the easy option here would be to just get a new kle flywheel

[Kickstart]

Hi

Electrically that will be the easiest as then (assuming you swap the crank cover and pickups) you have everything matching.

Not sure how well it will run though as then you will have the ignition timing for the detuned KLE engine which won't match the more tuned up GPZ engine.

All the best

Keith
____________________
Traxpics, track day and racing photographs - Bimota Forum - Bike performance / thrust graphs for choosing gearing

[stinkwheel]

[wildmetal]

god that rotors not cheap . think i will hang out for one off flebay . you never know one may come along

[Kickstart]

Hi

That is dirt cheap compared to an original Kawasaki part new. Think new from Kawasaki they are about £350.

All the best

Keith
____________________
Traxpics, track day and racing photographs - Bimota Forum - Bike performance / thrust graphs for choosing gearing

[Mick34123]

Hi all sorry for bringing this old thread up

I have the same problem, bought a n reg gpz500 and fitted engine and ancillaries to my kle, was running for abit then died (compression), swapped the kle engine back in using the gpz's loom ic box and magneto, using the gpz carbs too lost the kle ones

Bike turns over etc just does not fire, getting a spark and there is fuel on the plugs after i try starting it

Any help would be great thanks

[wildmetal]

Hi i would do a compresion test . i was getting a spark but i turned out that the piston rings were stuck in and one was broken . i ended up changing the engine from a gpz500 . i did however need to change the rotor and flywheel from the kle500 . it was then running ok

[Mick34123]

Compression on the engine is fine

Thing is the rotor etc from the kle was shattered thats why i replaced the bike with a gpz unit

Any other ideas ?

[Kickstart]

Hi

If you are getting compression, fuel and a spark at the right time it should start.

Stick a timing light on it and check the ignition timing.

All the best

Keith
____________________
Traxpics, track day and racing photographs - Bimota Forum - Bike performance / thrust graphs for choosing gearing

[Mick34123]

In my opinion thats what is wrong

its using all the gpz electrical side which did work when it was all on the gpz engine.

[Kickstart]

Hi

I would be far from certain, but it is an easy one to check. Only really likely though if the flywheel is triggering the ignition in a different position.

All the best

Keith
____________________
Traxpics, track day and racing photographs - Bimota Forum - Bike performance / thrust graphs for choosing gearing