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Old September 24th, 2019, 03:25 AM   #1
JmcEx2fifty
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...why not.... cheaper than rocker arms....

Um. Been hunting for a good deal on rocker arms for my 07 250 because the price of them is ridiculous but kinda just ended up with a donor Ex500... in progress. Will add pictures and update. Eventually. Can I keep 250 carbs and do maybe there's some chance the Jets out of the 500 can be installed on the 250 set?... experiment




...

#!$* it... ex500... into ex250f
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Old September 24th, 2019, 05:45 AM   #2
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Can’t use 250 carbs because:

- venturi needs to flow twice as much air
- jets have to deliver twice as much petrol
- spacing is wider on 500 engine


With spacers and flat bar-stock, you don’t have to cut & weld 250 frame...
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Old September 26th, 2019, 10:09 PM   #3
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Ok. Sir thank you
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Old October 25th, 2019, 09:13 AM   #4
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500 pregen. Mocking up motor position before the welding starts
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Old October 25th, 2019, 06:06 PM   #5
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I believe I still have a complete set of rocker arms out of my '99 that I kept for all this time since I sold the bike. What's your idea of a "good deal"? you know... just in case the 500 motor thing is a bust.
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Old October 26th, 2019, 09:40 AM   #6
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Quote:
Originally Posted by JmcEx2fifty View Post
500 pregen. Mocking up motor position before the welding starts

Coming along nicely! Make sure you quadruple-check and get that sprocket in exact location as original. Left-right, up-down, and laterally as well.
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Old October 27th, 2019, 07:02 PM   #7
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Fyi the Ltd 440 carbs and pre-gen electronics work on the 500. I’ve got two early engines sitting in my garage in case my 250 engine dies
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Old October 28th, 2019, 05:03 PM   #8
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Fyi the Ltd 440 carbs and pre-gen electronics work on the 500. I’ve got two early engines sitting in my garage in case my 250 engine dies
FYI, there are two generations of EX500 engines. They have different flywheels and igniters. The Gen1 flywheels have magnets that are known to grenade, and there were some transmission issues that were fixed in the Gen2.
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Old October 29th, 2019, 06:56 AM   #9
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Lmao I just saw your note at the bottom!

They were $100 for both engines, one with a fresh rebuild intended for arace bike. My 250 struggles with my sidecar sometimes and I might want more power.

Anyway, just throwing out that the ltd440 carbs work on the 500, might be a cheaper option.
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Old January 22nd, 2020, 09:39 AM   #10
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Return to the battle

Hey guys it's been awhile I had broken phone and a bunch of other stupid **** going on to where I made a lot of progress on the bike but I didn't document very much of it so start where I'm at I guess
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Old January 22nd, 2020, 09:42 AM   #11
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I'm actually about to pull the motor again to make some adjustments to my rear motor mount I've had it running everything sounds great. Great throttle response that sounds ****ing amazing pardon my French. Maybe I'll make an attempt to get these would be carburetor risers fog approved. Haha. Somehow between those and the way I chose to use undersized air filters in order to kind of battle the constant velocity carburetors I think I lucked out. Still running a little bit rich. More updates soon
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Old January 22nd, 2020, 04:58 PM   #12
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Great progress.
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Old January 24th, 2020, 03:35 PM   #13
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I was excited to get off work this morning and work on it. By the time I made it home it was a damn blizzard. My current work area has no roof or walls.... she stays under the cover for another day... :'(
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Old January 25th, 2020, 03:10 AM   #14
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All right this is for everybody to see the actual benefit of me swapping a 500R into my EX250. More than double hp...
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Old February 3rd, 2020, 12:51 PM   #15
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Okay not a lot of time to explain so I'm just going to post pictures that I have available I have the motor in and completely mounted next thing I'm working on is getting my radiator mounted and deciding where I'm going to mount my coils and I also have to start working on my fuel mixture because even at 1.75 turns out I am still rich as hell to the point where I think the damn thing is drowning when I get on it.
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Old February 3rd, 2020, 04:41 PM   #16
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Can somebody tell me how to make my tag read correctly I'm using the cluster from my 250 on the 500 and it is not reading correctly
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Old February 3rd, 2020, 10:21 PM   #17
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Isn't Northern Ninja doing a video on Ninja 250 with 500R swap too? He seems to know what he's doing. Check out his videos if you haven't already.https://youtu.be/AWEwtxsrjBA
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Old February 4th, 2020, 02:03 AM   #18
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Thanks @justanotherone1 I was just in touch with him about it, I'll print out the wiring diagrams and make a quick video tomorrow talking about the differences in the systems and how to wire it correctly if I get time. Should be uploaded tomorrow night or wednesday.
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Old February 5th, 2020, 12:33 AM   #19
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Not sure if you've resolved this or not yet but for further clarification or anyone looking to do this in the future, here's a little video I made explaining it.

https://www.youtube.com/watch?v=Xf0U...ature=youtu.be
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Old February 9th, 2020, 05:36 PM   #20
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Tach is done. Working on fuel issue now. Feels like I'm running the Bowls empty.
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Old February 9th, 2020, 07:34 PM   #21
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Measure actual vacuum going to petcock. Use rubber-T at petcock to tap into vacuum line going to petcock. This will discover leaks or cracks in line or issues with carbs supplying sufficient vacuum.
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Old February 12th, 2020, 10:57 PM   #22
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What should the vacuum be at
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