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General Category >> Rubber Side Down! >> Wiring an older motor
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Message started by Venturi on 01/31/20 at 07:08:06

Title: Wiring an older motor
Post by Venturi on 01/31/20 at 07:08:06

Hello all! In the coming months I am going to rebuild an older 4-speed motor (the 1987 I have has a damaged block, I going to use the top end from my ‘87on a bottom end I’m getting from Dave) I have two full wiring harnesses (a 2000 and an ‘05). When I get the older motor built, can I just plug and play with the newer harnesses? I have heard there might be timing issues with using a newer ECU with an older motor. I just didnt want to have to spend too much $$ on getting it running. Please let me know what you all think.

Title: Re: Wiring an older motor
Post by verslagen1 on 01/31/20 at 07:19:12

Yes, if you have an older bottom end and a newer electrics, you're gonna have to swap out the rotor for a newer one.
Timing is about 40° different.

Title: Re: Wiring an older motor
Post by Venturi on 01/31/20 at 07:38:58

Thanks Verslagen. Is that the only modification needed to get them working together?

Title: Re: Wiring an older motor
Post by verslagen1 on 01/31/20 at 09:47:01

6950434E13101A220 wrote:

Thanks Verslagen. Is that the only modification needed to get them working together?

Yes, all interfaces are the same, the motor mounts, decomp cable, electrical, exhaust, intake, and drive pulley are the same throughout the years.

Title: Re: Wiring an older motor
Post by Venturi on 02/01/20 at 07:31:41

Verslagen, by “rotor” you meant for the stator correct? Also called the flywheel? And by “newer one” it just needs to be post-1996?

Title: Re: Wiring an older motor
Post by batman on 02/01/20 at 08:49:26

The rotor turns around the stator ,it contains the magnets that act on the stator windings and the pickup coil for the TCI -( the one that's 40 degrees different from the 4 to 5 speed ) . You will need to buy or rent a special puller , and handle the rotor with care ,the magnets are earth magnets any sharp blows or dropping the rotor can ruin them. the bike does have a flywheel ,it sets on the shaft just behind the rotor.

Title: Re: Wiring an older motor
Post by Venturi on 02/01/20 at 08:52:34

Awesome. Thank you batman! This rebuild is obviously going to teach me a lot (I have never done a full motor rebuild). I appreciate ya’ll helping me along the way.

Title: Re: Wiring an older motor
Post by batman on 02/01/20 at 09:06:11

That's why we're here ,never be afraid to ask a question. the puller is listed as - rotor remover, part no. 09930-30721 by Suzuki $102.00, but you can find them online much cheaper, Motion Pro M50xP1.5 flywheel puller $67.49 .( will fit the Savage S40 and many other bikes)