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Message started by BuckRYCA on 06/02/12 at 21:09:58

Title: Issues replacing 1996 engine with 2003?
Post by BuckRYCA on 06/02/12 at 21:09:58

Transmission main shaft splines are gone after 22K miles on my 1996 Savage. Looking at 2003 Savage with 1500 miles for not much more than cost of transmission repair. Any known compatibility issues with engine swap?

Title: Re: Issues replacing 1996 engine with 2003?
Post by verslagen1 on 06/02/12 at 21:24:49

should be a direct swap, no known issues at all.

Title: Re: Issues replacing 1996 engine with 2003?
Post by Serowbot on 06/03/12 at 01:26:59

776473726D6066646F30010 wrote:

should be a direct swap, no known issues at all.

Yarp... ;)...

Title: Re: Issues replacing 1996 engine with 2003?
Post by 360k+ on 06/03/12 at 07:38:28

Getting the other bike also gives you a spare parts source too.

However, I'm curious as to why these splines would have stripped out so soon (or at all, for that matter)? Isn't the drive pulley a fairly tight fit on the drive shaft? I would think that play between these components would be a bad thing. That just seems strange to me. Savvy Savage motor guys, comment here?

Title: Re: Issues replacing 1996 engine with 2003?
Post by verslagen1 on 06/03/12 at 07:53:15

You'd have to press the pulley on to have no play at all.
The power pulses of the savage just tear these splines apart.

Title: Re: Issues replacing 1996 engine with 2003?
Post by 360k+ on 06/03/12 at 08:31:07

I know it's not a pressed fit, but any "clank" would be bad too, especially given these components transmit the thumpy power directly to the rear wheel. I would imagine the tolerance being a few thousands, at most.

In any case, 22k doesn't seem the usual service life of this component, or at least, I sure hope not! The other thing is, if Zuk anticipated early failure, I would hope that the pulley itself would have been made of slightly milder steel so that it wore out before the drive shaft as it's easier to replace.

Title: Re: Issues replacing 1996 engine with 2003?
Post by BuckRYCA on 06/03/12 at 17:06:24

Thanks for the replies. I think I'm going to buy the 2003 and do the swap. 22K miles is too soon. Details of my sad story are here: http://suzukisavage.com/cgi-bin/YaBB.pl?num=1338525938/15#15
Lesson learned is that a torque check on the front drive pulley retaining nut is a 4K miles maintenance item.