Engine from 500 to 250 please help

[123talis]

Hi I have Xciting 250 6/06 and recently I got stuck on a highway, engine just shut down and is damaged from inside. I have an offer of the whole Xciting 500 6/07 w/ 8000km crashed, but with fully functional engine vario etc (crashed face to something, front wheel and plastic is broken). Repair cost of my engine would be around 500-600 euro and XC500 is for 750 euro so I decided to buy it and replace whole engine and vario and etc. And what is even better, I will have the whole bike except of front plastic panel and front wheel.

My question is if the engine from XC 500 will fit my 250, or if its different. Kymco dealer service man told, that it will fit, he is 99,9% sure, but I am trying to get on that 0,1% left. So please Kymco owners help me to decide.

Any questions about my old engine are unimportant, I got my xc to service and after complete diagnostics that price went of (500 euro repair cost! + service)

[Hoolander2]

I will start by saying I don't know for sure -- I'm not an expert by any means.  I do have an '07 500. 

The final drive gear box is different so you will have to swap that too.

Air filter box and plastic intake snorkle are different -- you will need to swap.   

I'm sure many hoses for water and oil are different but you will have those. 

Have you considered putting your '06 front end and plastic on the 500?  That may be more simple and easier.  Paint plastic to match or just put all of your plastic on the 500?  Try to get the whole crashed bike with the damaged front end as there may be undamaged parts in the front end. This is assuming the 500 frame is not bent in any way.   

If you do that you will need to change your vehicle registration to the frame number of the 500.  Also notify insurance company of change in vehicle frame number so the bike is properly insured.

[Hoolander2]

Now, the more I think about this I think the engine swap would be easier. 

[123talis]

Yes repairing 500cc is my second option. But less work changing vehicle registration would be to replace engine and take it as a part of the vehicle which has been repaired. So replacing front  bodypart of XC 500 is harder and will take much longer. (500 is from the other country). Anyway whole engine and air filter, transmision (variator) etc, parts that are different are in perfect condition. So maybe more work in service, but less problems with insurance etc. So if the engine fits, I will try to replace it and see how it will works. Thank you, If someone have a different opinion, please let me know. But dont discuss off topic, I wont reply to that. Thanks

[spr0k3t]

I don't have the service/repair manuals for the X250 otherwise I might be able to offer some better suggestions.  I'm certain the final drive would need to be changed out for the difference in power.  You may have a problem with the swing arm... just don't know if there's a length difference in the x250 vs the x500.

[123talis]

dimensions of 500 and 250 are both exactly the same and in service manual swing arm settings there are no different pictures or how to-s for 250 and 500. So swing arm will be the same on both models. But thanks, I am ensured at least.

[spr0k3t]

That information will save you a lot of headaches for sure.  One of the things I would do is document the snot out of your progress, or shops progress for others who are interested in such a feat.

[123talis]

Yes If it will be possible I will post pics of reconstruction ASAP. XC500 will arrive in month I hope... Just before season, so its good timing.

[MrKymco]

wow. and i thought my little oil change mishap was bad!

good luck with all this, hope it works out 

[123talis]

Another difference is underseat space. XC250 has mobile charger plug on the front left side and X500 has it next to light, so on the front right side. Also shape of plastic under the seat is different, I think thats because of Air filter and engine differences. Anyway, crashed bike has undamaged seat etc, so it is just a detail. Just if someone is searching for other differences. Or is it just on 500R? I can not find video of trunk space XC 500 or 500i and R´s have the difference I am sure. Anyone with 500 or 500i to prove it?

[123talis]

Ok so here we are, today I brought my XC 500 and park it to the garage. On saturday I am going to show both bikes to service man and then we will decide what to do. XC500 will be spare parts bike, I think that frame is bend, It looks smaller and some parts doesnt fit they place correctly. Anyway, heres the photo. I hope everything will work, so wish me good luck please

[Hoolander2]

You will have good luck because you have a cat. 

[123talis]

Ok heres the update:

I have removed engine. cooling system, fuel tank and electricity from 250 and then today i have done same with 500i, then put 500i engine cooling etc to 250 frame.

On 500i, there is everything different. hooks (hope this is the right term) and small details on maybe 5-6 parts of the frame, different cooler, different tubes, different electricity (totally different, you have an injection in 500i and 250 dont have any). So engines are swapped, on monday I will try to make adjustements on frame to fit everything perfectly there. Next I will buy oil filter, engine oil and few other things. Everything works, there was just one damaged relay, but I have swapped it with one left from 250cc. Wish me luck to finish this all before the season starts.

[Hoolander2]

Good, Good Luck to you 123talis!  You've taken on a mighty big job.  Hope it goes well.