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engine swap wiring (Read 109 times)

jef.savage

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engine swap wiring
04/06/10 at 15:20:34

I just put a '96 engine in my '86. The list member who sold me the engine was nice enough to include the CDI. But the CDI woudn't fit onto my wiring harness so I bought the '96 harness. I spent half the day piecing together the two harnesses and got almost nowhere. Neither one of the sub-harnesses from the handlebars fits. The wire colors don't match up so I can see what to splice. There are multiple other problems.

I'm using the wiring diagrams from Clymer's. It looks like I might have to draw a whole new diagram using info from both. Anybody already done this? Any Ideas?

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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: engine swap wiring Reply #1 - 04/06/10 at 21:11:55 Dang, Dude, thats harsh. IDK the answer, but Im thinking I would have gone at it pretty much the same way. I would start w/ ignition & starting wiring, then branch out to the lites.
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jef.savage Serious Thumper Offline ridin' n slidin' Posts: 638 Boston, MA Gender:	Re: engine swap wiring Reply #2 - 04/07/10 at 02:04:31 It looks now like I should have just spliced the CDI connector from the '96 into the '86 harness. I don't know why I didn't think of that first. It should be fairly easy to restore and reinstall the '86 harness and then do that. Thanks for the sympathy.
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jef.savage

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ridin' n slidin'

Posts: 638
Boston, MA
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Re: engine swap wiring
Reply #3 - 04/07/10 at 16:17:35

OK, restored and reinstalled '86 harness. Everything worked. Decided to try to start it with '86 CDI. It fired right up and ran but not very well. Spliced in the connector for the new CDI and installed that. It ran much better but lots of backfiring. Then I remembered that I never got around to plugging the vacuum hose after the Raptor petcock install. Did that and now it runs like a champ. Still some backfiring but I'll deal with that later.

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Phelonius Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 1897	Re: engine swap wiring Reply #4 - 04/07/10 at 16:54:21 I know a guy with the entire wiring harness undamaged from an 06 s-40. It should match. Phelonius
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jef.savage Serious Thumper Offline ridin' n slidin' Posts: 638 Boston, MA Gender:	Re: engine swap wiring Reply #5 - 04/07/10 at 18:30:20 Thanks, Phelonius, I'm all set. The catch was that the new harness does not match. That;s why I went back to the old one and just spliced in the CDI connector. I do appreciate you taking time to respond. jef
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savagedml Full Member Offline Paid Alliance Membership (07/09) Posts: 246 Portsmouth, VA Gender:	Re: engine swap wiring Reply #6 - 04/09/10 at 11:41:12 Jef: Thanks for the earlier call. I'm thrilled that everything worked out for you in the end. I know you'll get good service out of that engine. Now be careful, because if you figure out a way to get rid of ALL of the backfiring, noone will ever believe you have an authentic SAVAGE Stay in touch, Darrell
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