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Old April 28th, 2010, 08:37 PM   #1
ztrack157
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The Ex 500 Engine swap with pics

Yes you read it right. We have an ex500 motor installed and running in a Ninja 250. The pictures are rough I will add more and video as we tidy things up.
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File Type: jpg EX 500 engine.jpg (79.0 KB, 599 views)
File Type: jpg EX 500 engine 2.jpg (86.9 KB, 556 views)
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Old April 28th, 2010, 08:42 PM   #2
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Very cool.
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Old April 28th, 2010, 08:49 PM   #3
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Matt... who's "we"???
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Old April 28th, 2010, 08:59 PM   #4
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That's pretty coool
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Old April 28th, 2010, 09:03 PM   #5
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I've been seriously wondering about just this possibility. I'll be curious as to how it handles, how the frame deals with the increased power, etc. What a great way to extend the life of the 250 for many, as EX500 engines and parts should be plentiful.
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Old April 28th, 2010, 09:05 PM   #6
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Kelly if I ever say we, I am refering to myself and sportisi.
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Old April 28th, 2010, 09:31 PM   #7
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Very cool. Talk about a "sleeper" bike.
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Old April 28th, 2010, 10:24 PM   #8
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Some more pictures.
Attached Images
File Type: jpg IMG00164-20100429-1012.jpg (106.8 KB, 341 views)
File Type: jpg IMG00165-20100429-1012.jpg (123.8 KB, 367 views)
File Type: jpg IMG00168-20100429-1013.jpg (115.1 KB, 296 views)
File Type: jpg IMG00169-20100429-1013.jpg (102.1 KB, 269 views)
File Type: jpg IMG00170-20100429-1014.jpg (124.1 KB, 343 views)
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Old April 29th, 2010, 04:37 AM   #9
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Did you use angle intake boots to fit the carbs?

That is very cool .
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Old April 29th, 2010, 06:23 AM   #10
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I was wondering when someone was going to try this. Sleeper for sure...
The questions now are...

1. Will the frame handle it?
2. Will the fairings fit over it?
3. Is the 140 rear gonna work?
3. How did you do it?
4. How much will it cost for the mounting kit from sportisi?
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Old April 29th, 2010, 07:01 AM   #11
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wow thats cool I want one
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Old April 29th, 2010, 07:47 AM   #12
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Old April 29th, 2010, 11:09 AM   #13
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Quote:
Originally Posted by bdavison View Post
I was wondering when someone was going to try this. Sleeper for sure...
The questions now are...

1. Will the frame handle it?
2. Will the fairings fit over it?
3. Is the 140 rear gonna work?
3. How did you do it?
4. How much will it cost for the mounting kit from sportisi?
1.yes new tabs were made to hold it in place. the engine weighs about 30 pounds more than the 250 engine.

2. yup

3. yes

4. secret for now

5. I will let you know
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Old April 29th, 2010, 11:38 AM   #14
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Matt,
Please post pics when you have the fairings on. Great project.
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Old April 29th, 2010, 12:59 PM   #15
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Ahhhh, so hinting at a conversion kit that "we" will be producing soon?
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Old April 29th, 2010, 01:06 PM   #16
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its a thought but not a fact yet.
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Old April 29th, 2010, 01:17 PM   #17
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Be interesting to see how front/rear weight bias changes. Guessing there is minimal room for adjustment in the frame and you have to go with what the frame space offers.
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Old April 29th, 2010, 05:25 PM   #18
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why not use the zxr400 motor?
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Old April 29th, 2010, 07:28 PM   #19
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Motor is to big and parts are not readily available.
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Old April 29th, 2010, 07:51 PM   #20
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why not use the zxr400 motor?
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Why not use the ZX10 motor?
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Old April 29th, 2010, 08:08 PM   #21
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Not enough horse power craig. srt v10 all the way
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Old April 29th, 2010, 08:36 PM   #22
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busa motor
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Old April 29th, 2010, 09:14 PM   #23
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busa motor
HERESY!!!!!! You must be burned at the stake for suggesting such a mix. Polluting a ninja with a Suzuki motor, how could you think of such a thing?
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Old April 29th, 2010, 09:16 PM   #24
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don't make me put a v twin harley in there
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Old April 30th, 2010, 06:44 AM   #25
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A V-Twin Buell motor would be cool...lol
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Old April 30th, 2010, 07:09 AM   #26
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A Duc L Twin sounds cool but won't go with the front frame tubes. I think the 500 motor makes a lot of sense as there are a ton of them out there.
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Old April 30th, 2010, 07:22 AM   #27
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There's a business opportunity here for some enterprising mechanic. Someone who specializes in doing this conversion.

This level of mod is serious enough that it could intimidate a lot of people who really want it. Or, worse, tempt them to try something they're not ready to handle from a mechanical skill standpoint.
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Old April 30th, 2010, 07:34 AM   #28
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OK, not for everyone, but to really rip from corner to corner - KX250 or KX500 single cylinder 2 stroke engines. Would have to run premix in the tank and find away to fit expansion chambers, or a KX450F single cylinder 4 stroke.
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Old April 30th, 2010, 09:05 AM   #29
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If you do not know how to tig weld or do electric then this is certainly not the mod for you.
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Old April 30th, 2010, 09:26 AM   #30
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well it does look nice!! Thats what i wanted to do with mine not too long ago...but i kinda chickened out cuz i really like my ninja and you know...f-ing it up is not in my book. Once ur done and this thing works...i'll pay you to convert mine!
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Old April 30th, 2010, 01:00 PM   #31
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Are you planning on doing a dyno chart when it's done? That would be interesting.
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Old April 30th, 2010, 05:42 PM   #32
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Very impressive! though i never understood motor-swaps on bikes. I mean hows it gonna handle now with the extra weight?
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Old April 30th, 2010, 07:02 PM   #33
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lools like a charlie foxtrot to me

you need to be a hard core mod junkie for this one
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Old April 30th, 2010, 07:17 PM   #34
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How bout a swap kit for one of these........

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Old April 30th, 2010, 07:25 PM   #35
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I am not putting a rolls turbine in there.
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Old April 30th, 2010, 07:37 PM   #36
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I have wondered about whether this would be possible and am very interested in your progress. Please keep the updates coming!

Bravo!

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Old April 30th, 2010, 11:05 PM   #37
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Wow, that is so intense..... I fold.
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Old May 2nd, 2010, 03:47 AM   #38
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So who's gonna be the first to do the 650 engine swap?

FYI the external dimensions of the 650 are smaller then the 500.
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Old May 2nd, 2010, 09:35 AM   #39
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Very interesting. Would be a very cool project. Wouldnt wanna do it to my baby but find a salvage 250 with a good frame and engine, sell the engine, and by a 500. That would be fun. twice the hp is always fun as long as weight isnt changed to drastically, then again you could always then take it to a suspension expert to get that sorted.


Matt, has anyone seriously riden the bike yet or is it still in R&D where that isnt possible?
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Old May 2nd, 2010, 09:36 AM   #40
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It is smaller but then you get into the fuel injection crap. Also the mounts on the motor are not as easy to work with.
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