1986 Kawasaki 454ltd bobber project

[kawibobber]

I have a 1986 bobber with the 454 ltd engine. well the engine sat for a long time with no spark plugs, carbs, or exhaust and the radiator not plumbed. also it was sitting out side. i haven't cracked it open yet bug the spark plug holes are filled with gunk. so its looking like the engines trash. so I'm looking for some info on replacing it with a higher performance engine. maybe even something i can build up a bit. i heared that the ninja 500 engines will fit and i want to go the chain route but i would like to know what's all involved and what years to look for.

[eaglerider]

The Ninja 500 is externally, the same as the 454 (the 454 was the R & D engine for the 500), so will bolt right in. However, the stator cover and flywheel from the 454 engine must be swapped into the 500 engine, in order to make the 500 run in the 454 chassis, and, if you want to retain the tach, the 454 valve cover (include the tach drive parts) and at least the intake cam (it has the tack drive worm gear on it) must be swapped into the 500 engine. For chain rear drive to match the Ninja engine, obtain the chain drive rear assembly from a Ninja 500, remove the 454 belt drive sprocket drive...the chain drive Ninja unit will fit right on the 454 wheel.

[kawibobber]

So if I'm starting from basically a rolling chassis do i still need all theses parts? Or does it kind of render them useless? I'm pretty much going all aftermarket or custom including the wiring harness. Could i get an aftermarket tach to use with the 500 engine?

[eaglerider]

If you go that route, using a 500 wiring harness would be easier. The reason for the parts change for the 500 in the 454 chassis, is that the 454 and 500 fire different, therefore the wiring harness is different on the two. The 500 does not have a tach (at least the Vulcan does not). I am not an electrical guy, so doing a "custom wiring harness" is way, way above my head...LOL. Don't know how the Ninja is...possibly electronic.

[kawibobber]

What years for the ninja 500 engine should i look for? And if i went with the vulcan 500 engine what do i exactly need to replace for the tachometer? i would really like to use a ninja 500 and tach if possible that way parts would be easier to find. Like i said the 454 engine is trashed in my bike so i have no idea if the cam is in good or bad shape. i guess time will tell when she gets pulled apart this weekend but if i do not have to tear it apart i do not want to waste my time lol.

[eaglerider]

The Vulcan and Ninja 500 are basically the same engine...The Vulcan is de-tuned. 1990 thru 1995 are belt drive, like the 454. The same parts from the 454 must be used in both engines if you put them in the 454 chassis, using the 454 wiring harness. As far as the tach thing, you could always run without one.....the Vulcan does not have a tach, and truthfully, I am not too up to date on the Ninja, but I think the Ninja has an electronic tach.

I installed a 1994 Vulcan engine in my 454...changed everything ( stator cover, flywheel, etc) over from the 454 engine, except the cams. About somewhere in that year, the Kawasaki plant "ran out" of EN 500 engines for the Vulcan, so they went over to the Ninja side, and "borrowed" some EX 500 Ninja engines, converted them to belt drive....I was fortunate to have gotten one of those...and on top of that, it had a set of competition cams installed in it!! All I had to do was use the 454 valve cover & tach drive part, and I was set to go.

[gooch]

Can you switch out the jugs and pistons on a 454 to the ex500? I figure I'd need to switch intake cams and flywheel rotor.