ER5 Engine Swap / Build

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fastbob
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ER5 Engine Swap / Build

#1 Post by fastbob » Tue Aug 07, 2018 8:01 pm

Ok, I've taken delivery of my £50 " Bargain " ER5 engine . I haven't decided exactly what I'm going to do with it yet . It mostly depends on if I can determine whether the gearbox works or not . ER5s have a peculiarity that means they will not change from first to second unless they are in drive mode and moving . The seller apparently didn't know this and sold it dirt cheap in the belief that it was knackered. My assistant Bob has examined the engine and has given his approval to proceed . Either that or some other moggy has pissed on it .
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Re: ER5 Engine Swap / Build

#2 Post by Mr Fro » Tue Aug 07, 2018 9:52 pm

Don't think it's just the ER5, I've not had a Kwak that'll go straight to second.

Shame it's short as you could have made a go-kart or something.

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Re: ER5 Engine Swap / Build

#3 Post by Ricky » Tue Aug 07, 2018 10:05 pm

:stupid:

Made my kwak ninja 250 a bitch to bump start :evil:
Live forever or die trying.

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Re: ER5 Engine Swap / Build

#4 Post by fastbob » Tue Aug 07, 2018 10:13 pm

Mr Fro wrote:
Tue Aug 07, 2018 9:52 pm
Don't think it's just the ER5, I've not had a Kwak that'll go straight to second.

Shame it's short as you could have made a go-kart or something.
I seem to recall that my old Z1000 ST would go into second because many's the time I had to scoot it down the drive to start it .

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Re: ER5 Engine Swap / Build

#5 Post by Mr Fro » Wed Aug 08, 2018 7:46 am

Ricky wrote:
Tue Aug 07, 2018 10:05 pm
:stupid:

Made my kwak ninja 250 a bitch to bump start :evil:
You try doing it with a 636: run, puff, run, puff, jump on, dump clutch, skiiiiid... Shit.

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Re: ER5 Engine Swap / Build

#6 Post by Mississippi Bullfrog » Wed Aug 08, 2018 7:47 am

Nah - Bob's just thinking how much cat food you could have bought for the price of a chunk of metal.

If you're doing a take it bits, put it back together, hide the bits left over thread - then lots of piccies please. I love engine builds.
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Re: ER5 Engine Swap / Build

#7 Post by fastbob » Wed Aug 08, 2018 8:56 am

Mississippi Bullfrog wrote:
Wed Aug 08, 2018 7:47 am
Nah - Bob's just thinking how much cat food you could have bought for the price of a chunk of metal.

If you're doing a take it bits, put it back together, hide the bits left over thread - then lots of piccies please. I love engine builds.
63 tins worth to be precise.

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Re: ER5 Engine Swap / Build

#8 Post by Speedy23 » Wed Aug 08, 2018 9:35 am

Cat order of priorities: Me, Me, Me, Me, stick person who supplies food......
Oh my God, what's happened? I don't know man...I just got here myself!

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Re: ER5 Engine Swap / Build

#9 Post by Hoggs » Wed Aug 08, 2018 8:33 pm

Ricky wrote:
Tue Aug 07, 2018 10:05 pm
:stupid:

Made my kwak ninja 250 a bitch to bump start :evil:
Mr Fro wrote:
Tue Aug 07, 2018 9:52 pm
Don't think it's just the ER5, I've not had a Kwak that'll go straight to second.

Shame it's short as you could have made a go-kart or something.
Both of these :lol: My ninja won't go into 2nd when stationary either
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Re: ER5 Engine Swap / Build

#10 Post by fastbob » Wed Aug 08, 2018 9:00 pm

We'll I've spun the clutch by hand while trying to shift gears but it isn't looking good . Next job will be to scrape off 19 years worth of chain lube so I can get into the shift mechanism. Never mind its just a bit of fun , I've got all winter to build an engine out of the best ( least worse ) of the two . The one I've bought has a good primary chain in it which is worth way more than £ 50 alone .

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Re: ER5 Engine Swap / Build

#11 Post by JRH » Thu Aug 09, 2018 7:36 am

My GPX would only go into second gear when the rear wheel was moving, so rather than turning the clutch have you tried turning the drive cog.
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Re: ER5 Engine Swap / Build

#12 Post by fastbob » Thu Aug 09, 2018 11:50 am

JRH wrote:
Thu Aug 09, 2018 7:36 am
My GPX would only go into second gear when the rear wheel was moving, so rather than turning the clutch have you tried turning the drive cog.
I see what you mean. I have all the plates out and I'm spinning the inner hub which is slowly rotating the rear sprocket in first . So far I haven't been able to get any other gears but this is by no means conclusive.

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Re: ER5 Engine Swap / Build

#13 Post by Mississippi Bullfrog » Fri Aug 10, 2018 7:38 am

What does Bob think? After all, he's clearly the key played in this process.
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Re: ER5 Engine Swap / Build

#14 Post by fastbob » Sat Aug 11, 2018 8:25 am

Mississippi Bullfrog wrote:
Fri Aug 10, 2018 7:38 am
What does Bob think? After all, he's clearly the key played in this process.
Bob's lost interest , I borrowed a Haynes manual from the library and every time I try to read it he comes and sits on it .

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Re: ER5 Engine Swap / Build

#15 Post by fastbob » Sat Aug 11, 2018 8:39 am

A quick update, despite the crusty exterior everything internal is absolutely mint so far . I've had the sump off and there were no metal particles at all and surprisingly little sludge . From here I can see most of the gearbox and again it looks mint , no chipped teeth or worn dogs . The external shifter mechanism is in good order so I am beginning to suspect that the fault lies in the grooves in the selector drum . I seem to be able to get neutral and SECOND rather than neutral and FIRST as I initially thought. So next job is going to be to split the cases and do some inspecting and measuring . The good news is that there are loads of selector drums and whole gearboxes on eBay for very little money.