ER5 Engine in a KLE Problem
 

The magnets in my KLE Went BANG and spread all over the gearbox also took out the stator, looks like spagettie, so I had an ER5 hanging around so put that in.

I Have to use the ER5 Cover & Stator for obvious reasons

I notice that you have to change the Module to work with the ER5 Stator and cover, do they mean the CDI / ECU / Igniter known by many names?

Thanks all

MaDbrIT

Hi, I have a similar problem.

I'm just about to fit a 2001 GPZ500 engine into my 1992 KLE500, which is slightly less technical than using the ER5 engine, because the GPZ and KLE motor are identical apart from cams, carbs and ignition.

The GPZ is a gen2 engine and has the updated flywheel with enclosed magnets, however the CDi black box is different. My KLE has a Denso unit and the GPZ uses a Mitsibushi unit. I suspect that the advance curve is different on the KLE ??

Has anyone done this conversion ? If so what did you do ?

According to the GPZ & KLE wiring diagrams, the two units have the same functions & same colour wires, so I could just leave the KLE unit on, or I could splice some different connectors onto my loom & fit a GPZ module.

I don't really want to go down the route of turning the Gen2 flywheel into a gen1 replacement and using that + the old KLE pick-ups etc, because then I'm stuck with it if I want to use the GPZ carbs + cdi to get better performance..

Again if anyone has fitted a GPZ engine to a KLE I'd be grateful of what parts work well together.

Thx