Hitchcocks Forum

Hello everyone I have a 500 electric start classic 2002 which has a sheared conrod which damaged barrel and piston. I also have a 1996 500 kick start engine complete and running.
I guess my question is rather than rebuilding the electric start engine can I simply slot in the older 500 kick start engine using the ES gearbox , alternator and electronic distributor plate it has so that it keeps the wiring colour coding the same. Will engine sprocket and clutch basket be a straight swap ( I have inner and outer primary covers for the kickstart engine too ).
I will rebuild ES engine at a later date but just thought this could get me on the road quicker !
Any thoughts, suggestions welcomed, thanks in advance !

can see any problem only there could be a few imperial nuts and bolts.you have nothing to loose go for it

Go for it. I have put a Electra X engine in a 1954 Bullet frame - so your swap should be easy.

Hi Vespa. You might find a very slight difference between the splines of the E/S engine sprocket and the K/S one. I discovered this when converting my E/S to kickstart-only. The K/S-only sprocket, although it fitted, was a bit too sloppy on the splines of the E/S crankshaft for my liking (I eventually had the starter gear cut off my original E/S sprocket to restore a snug fit on the splines). Also note that the E/S inner primary case is not interchangable with the kickstart one, due to different spacing of the screw-holes on the crankcase (although this can be rememdied by drilling and tapping new screw-holes into the crankcase - there is provision in the crankcase casting to enable this). Our hosts used to sell a KS-only conversion kit, complete with notes on how to this.

Hello Devon John and graham43 thanks for the encouragement !
Barry N thanks for the variety of info, very helpful . Do you guys know if I can use the ES stator and rotor to keep wiring plug n play or should I use the three wire original KS stator ?
Many thanks guys very helpful indeed.

Hi Vespa, I might be able to make use of your expired engine, if you are offloading it? Regards, Paul.

Rotor and stator with fit. It's the Electra that's the odd one out.

Isn`t the 2002 Bullet AC/DC electrics? I know my 2003 Sixty5 is, but the `96 one won`t be. They use different alternators, and presumably different headlight wiring?

Ray

Er..... I see Pete has already covered this, sorry. I guess if you are able to fit the newer alternator to the older engine it will work as normal.

Ray.

Thanks for your input PeteF and Nettshubby much appreciated and I will keep everyone updated
On progress. Bullet whisperer will keep your offer in mind thanks.