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General Category >> Rubber Side Down! >> 1986 & 2004 Suzuki Savage Combo
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Message started by Nathan on 03/27/16 at 23:39:16

Title: 1986 & 2004 Suzuki Savage Combo
Post by Nathan on 03/27/16 at 23:39:16

Hey Guys,

I have a 1986 and a 2004 Savage and I'm looking to take the best of both bikes and put them together. Are those years compatible? My manual is 86-07 so I assumed it would be okay but thought I'd ask the pros before I begin tearing.

Thanks!
Nathan

Title: Re: 1986 & 2003 Suzuki Savage Combo
Post by Dave on 03/28/16 at 04:03:11

There are some parts that you need to keep with the engine, and not interchange.....and the wiring harness might be involved in that. I am assuming you are using the 2003 engine as it is a 5 speed and has the torque limiting gear for the starter motor. You need to use the rectifier and wiring that goes with that engine as the number of wires on the connector are different. (Don't switch the left engine cover/stator assembly to make the wires match, as the electrical pickup for the ignition is in a different spot and the engine will run poorly....you have to switch the rotor if you switch the left engine cover).

There is also some wiring changes.....the 86 model has a light for the sidestand to show you if the stand is down....the 2003 model has a safety interlock that will kill the engine if you put the bike in gear with the sidestand down.

It would help us to know which frame/wiring harness and which engine you are wanting to use.

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

Title: Re: 1986 & 2003 Suzuki Savage Combo
Post by Nathan on 03/28/16 at 14:43:47

AGH sorry my mistake my other bike is a 2004. Okay, that's great information to know, I figured there would be some electrical wiring issues.

Dave what I'm looking to do is switch over everything (that I can, wire permitting)
from my 2004 savage just to utilize the frame of my 86 savage. The main reason I'm doing the swap is to learn more about my bike for a fun project with my dad along with being able to plate my bike as an 86 (now antique) saving me a +$1000/year.

Title: Re: 1986 & 2003 Suzuki Savage Combo
Post by gizzo on 03/28/16 at 15:20:20

01342F3C3C2A3F222328460 wrote:

being able to plate my bike as an 86 (now antique) saving me a +$1000/year.

That's a good reason! wow. is that for insurance?

Title: Re: 1986 & 2003 Suzuki Savage Combo
Post by Dave on 03/29/16 at 05:40:32

In 2004 there were significant changes to the wiring harness - especially the handlebar electrical controls which gained the 4 way flasher and a passing light. You need to install all the wiring and electrical components from the 2004 onto the 1986 frame. The connectors for the turn signals are different types, the rectifier plug is different, etc.

Title: Re: 1986 & 2004 Suzuki Savage Combo
Post by Nathan on 03/29/16 at 12:51:57

Yeah insurance in Saskatchewan has been skyrocketing for bikes. It's a bit of a problem!

Title: Re: 1986 & 2003 Suzuki Savage Combo
Post by Nathan on 03/29/16 at 20:48:14

6A515C4B5A564D4B5058554A390 wrote:

Okay Dave that's great to know. Currently I have the 86 completely stripped down to the frame so when we build it back up we're going to take every single piece off of the 04 and put it onto the bike. Is this doable?

Title: Re: 1986 & 2004 Suzuki Savage Combo
Post by Dave on 03/30/16 at 08:33:07

Yes....no difference in the frames that I am aware of (other than serial number).

Title: Re: 1986 & 2004 Suzuki Savage Combo
Post by jrobeson18 on 03/30/16 at 11:15:59

My insurance on the bike is 125$ per year....