Forum

[Vespa66]

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 !

[devon john]

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

[Graham43]

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

[Barry N]

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.

[Vespa66]

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.

[Bullet Whisperer]

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

[PeteF]

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

[Nettshubby]

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

[Nettshubby]

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.

[Vespa66]

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.