SuzukiSavage.com - Using different year engine

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Using different year engine
01/04/09 at 05:53:02

I have a 1987 Savage. The engine went bad, so I purchased an engine from a 1996 Savage. I know the trans is now 5 speed instead of 4 speed. Everything fit where it was suppose to. We had the engine on in a couple of hours. The bike does run, but when you go to shift the bike pops and backfires pretty bad. I bought the engine based on people telling me it would work. I have had the bike looked at twice, and I am being told they can not fix it. I put on the carburator from the newer engine also. I really like this bike, and I just know someone has run it this before.

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Demin Serious Thumper Offline We need more chlorine in the gene pool Posts: 2435 Warren,Ohio Gender:	Re: Using different year engine Reply #1 - 01/04/09 at 06:24:12 Did you put the electrics from the newer engine on with it?There is a difference.
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dieseldoll YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 6	Re: Using different year engine Reply #2 - 01/04/09 at 06:31:08 I bought the wiring harness off of the 1996, and I was told the wiring was different and could not be used. I am thinking of doing it myself. I am pretty sure I will have to splice in some of the wires, but I am willing to try it.
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28884 L.A. California Gender:	Re: Using different year engine Reply #3 - 01/04/09 at 07:22:09 There's a difference in the CDI box, you'll want to use one from the same range of years.
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dieseldoll YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 6	Re: Using different year engine Reply #4 - 01/04/09 at 07:51:39 I have the CDI box from the 1996. Will I have to splice the wires in to make it work?
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28884 L.A. California Gender:	Re: Using different year engine Reply #5 - 01/04/09 at 07:55:16 Is it a different connector?
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dieseldoll YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 6	Re: Using different year engine Reply #6 - 01/04/09 at 08:44:31 Yes, the connector is different. Some of the connectors in the harness are the same, and some are not the same.
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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Using different year engine Reply #7 - 01/04/09 at 10:42:49 Typing back & forth is too slow & tedious. Sometimes, just making a 10 minute phone call solves the whole hassle. IF I knew how to help Id call ya, maybe someone else will.
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Paladin.

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Re: Using different year engine
Reply #8 - 01/04/09 at 11:24:19

dieseldoll wrote on 01/04/09 at 05:53:02:

I have a 1987 Savage. The engine went bad, so I purchased an engine from a 1996 Savage. . . . when you go to shift the bike pops and backfires pretty bad. ....

From what I've read about the bikes, the newer engine was set up a LOT leaner than your old '87, which is the casue of the infamous Savage pops and backfires. IOW, sounds normal to me.

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dieseldoll YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 6	Re: Using different year engine Reply #9 - 01/04/09 at 11:28:24 Thank you for all the help so far. I think I am going to take the chance and work in the newer wire harness. At this point I don't have much to lose now.
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T Mack 1 - FSO

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Re: Using different year engine
Reply #10 - 01/04/09 at 19:55:12

Diesel Doll,
Get your self a manual. Either a clymer or a factory one. They both have wiring diagrams which will help a bunch. It will help you with some of the real minor differences. Yes, the differences are minor so it can be done.

For the wiring diagrams, I like the factory one better. FYI, my training is as a electronics tech.

T Mack

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Rockin_John

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Re: Using different year engine
Reply #11 - 01/04/09 at 21:47:25

You've gotten some good advice so far...

And IMO, you are thinking right in trying to work the new harness and CDI unit into the bike now. Of course you'll have to do some work-around to get all the old stuff to work from the new harness; but it should be a lot less trouble than trying to patch the new CDI unit into the old harness. Or at least that's the way I'd approach it in hopes it was the shortest and easiest way of going at it. Hope it all works out and you don't need any of the later model charging circuit stuff, like the diode pack, to be compatible with the newer stator/rotor in the alt/gen set. I don't think those things are a problem though. The main difference was with the CDI I think. As someone mentioned, the newer ones ran much more lean, and the CDI: timing probably had to be adjusted to keep from burning up pistons! I've heard it rumored before that the older model CDI has a better performing timing curve in it; but honestly, having had both, I can't tell much difference beyond favoring the 5-speed transmission a bit.

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dieseldoll YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 6	Re: Using different year engine Reply #12 - 01/05/09 at 18:04:13 I thank both of you for the information. I am going to try this way. I am going to get a wiring diagram from a dealer.
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