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Message started by Kris on 03/20/12 at 20:28:22

Title: Engine swap question
Post by Kris on 03/20/12 at 20:28:22

I'm looking at swapping out my dead motor for a newer one and was curious if a newer engines mounts would match up. I've got an '89 and was looking at say an '05 engine. Upon looking at pictures, it looks like everything mounting wise is identical. Can anyone confirm that a swap like this would be possible? Thanks.

Title: Re: Engine swap question
Post by justin_o_guy2 on 03/20/12 at 20:49:52

Everything is a direct swap, but th electronics are changed, So, you gotta swap some things out,, maybe even have to have a wiring harness,, IDK,,

Title: Re: Engine swap question
Post by verslagen1 on 03/20/12 at 21:46:32

Motor mounts no problem, direct swap.

However, the cdi is different. the work around is to swap the rotor.

http://suzukisavage.com/cgi-bin/YaBB.pl?num=1280002938

Title: Re: Engine swap question
Post by Kris01 on 03/21/12 at 19:51:51

So you're the reason why I couldn't register my first choice in names! ;D

(Sorry to hijack your thread!)

Title: Re: Engine swap question
Post by greenmonster on 03/22/12 at 06:51:46

Or if you don't want to crack open the motor you just picked up, you can change the CDI. It's not that much work, you just need to get the wires right.

Title: Re: Engine swap question
Post by Demin on 03/22/12 at 06:58:42

I'm getting ready to do one right now.The only thing is,the engine I'm buying is missing the left cover and stater gears.I hope the '86 one will bolt to an '01.I've seen a thread on it,just never paid attention.Never needed it 'til now.

Title: Re: Engine swap question
Post by verslagen1 on 03/22/12 at 08:05:59

yes the cover and gears are interchangeable.

post '95 covers have a ~1/2" deeper pocket in them for the torque limiter gear.

as long as you swap the cover and gear together, you'll have no problem.

However, highly recommend the torque limiter gear.

Title: Re: Engine swap question
Post by Demin on 03/22/12 at 14:05:35

I'll have to try and get the newer gears.They didn't come with it.I just got back from picking mine up.'01 with 12,xxx.$500.00. >:(

Title: Re: Engine swap question
Post by verslagen1 on 03/22/12 at 18:53:35

http://www.ebay.com/itm/1996-SUZUKI-LS650-ls-650-savage-side-cover-WITH-STATOR-case-generator-stator-/300610515097?pt=Motorcycles_Parts_Accessories&hash=item45fdc87099&vxp=mtr

Title: Re: Engine swap question
Post by Kris on 03/24/12 at 05:51:10

How difficult would a CDI swap be vs. opening up the motor. I have no problems cracking the motor open, but if a CDI swap is easier, I'm game for that.

Title: Re: Engine swap question
Post by Demin on 03/24/12 at 07:19:33

Just changing the CDI would mean changing wiring harness.My new engine didn't come with a charging system,so I'm going to change out the electrics in the engine.Without the rotor on,it's right there.

http://p1.bikepics.com/2012/03/24/bikepics-2371087-800.jpg

Title: Re: Engine swap question
Post by thabrock on 10/06/12 at 18:34:04

I need info. You guys seem to be helpful.

Will a 02 wire harness direct swap to a 97 with no problems?

Title: Re: Engine swap question
Post by thabrock on 10/06/12 at 19:02:14

I may have answered my own question.

http://www.ebay.com/itm/Suzuki-LS650-LS-650-Savage-1996-2003-Main-Wire-Harness-Wiring-Harness-130610-/350613710225?pt=Motorcycles_Parts_Accessories&hash=item51a234a591&vxp=mtr