SuzukiSavage.com - Newer Engines

greenmonster

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Newer Engines
04/18/11 at 14:06:30

Hi guys,

I'm looking at a new engine. Is there any reason that I wouldn't be able to put an 05 Engine into my 86 frame?
I tried a search and came up a little short on hits. Unfortunately I'm at work so I'm not really able to give the search feature the attention that I normally do when looking for info. If there is a thread out there that answers this, sorry. I throw myself on your collective weath of knowledge and infinate wisdom.

GM

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MotoBuddha Serious Thumper Offline Let's roll! Posts: 1416 Charlotte, NC	Re: Newer Engines Reply #1 - 04/18/11 at 14:29:17 You might want to get the digital controller box thingamajig with it. Otherwise, whee, an extra gear!
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thumperclone

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Re: Newer Engines
Reply #2 - 04/18/11 at 15:08:42

greenmonster wrote on 04/18/11 at 14:06:30:

Hi guys,

I'm looking at a new engine. Is there any reason that I wouldn't be able to put an 05 Engine into my 86 frame?
I tried a search and came up a little short on hits. Unfortunately I'm at work so I'm not really able to give the search feature the attention that I normally do when looking for info. If there is a thread out there that answers this, sorry. I throw myself on your collective weath of knowledge and infinate wisdom.

GM

get a clymers or a suzuki service manual..
the wiring harnesses are different
but it has been done

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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: Newer Engines Reply #3 - 04/18/11 at 15:37:02 yes an any year engine will fit any year frame. only diff is the CDI and wiring harnace. I think all the engine connectors are the same. CDI box has a different connector, but same number of wires.
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greenmonster Senior Member Offline Hellooooo Nurse! Posts: 420 Vancouver BC Gender:	Re: Newer Engines Reply #4 - 04/18/11 at 16:29:30 would the cdi be the thingamajig that motobudda was talking about?
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MotoBuddha

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Re: Newer Engines
Reply #5 - 04/18/11 at 16:34:49

Here's a question, though: at what point does a collection of engine parts from various years require a different CDI and wiring harness? I mean, except for the change to 5 speeds and a better starter gear thing, all the metal parts are the same. What makes the differences in the electrical system necessary? Or are they not necessary but just a matter of Suzuki making little tweaks over the years, or sourcing different suppliers, or whatever? You can interchange the metal parts, but why not an entire engine?

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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: Newer Engines Reply #6 - 04/18/11 at 16:42:56 this might clear it up for you... http://suzukisavage.com/cgi-bin/YaBB.pl?num=1280002938
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MotoBuddha Serious Thumper Offline Let's roll! Posts: 1416 Charlotte, NC	Re: Newer Engines Reply #7 - 04/18/11 at 17:25:04 OK, so the flywheel.
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greenmonster Senior Member Offline Hellooooo Nurse! Posts: 420 Vancouver BC Gender:	Re: Newer Engines Reply #8 - 04/18/11 at 17:32:47 while we're at it, are the jugs interchangable? I think they are but I don't want to be mistaken on something this important.
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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: Newer Engines Reply #9 - 04/18/11 at 17:51:25 greenmonster wrote on 04/18/11 at 17:32:47: while we're at it, are the jugs interchangable? I think they are but I don't want to be mistaken on something this important. I think so, not much different if they are.
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greenmonster

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Re: Newer Engines
Reply #10 - 05/16/11 at 14:10:21

So I've installed a new motor in Nessy. Everything went really well. I've only a few questions for you fine folks.

1. The regulator/rectifier wires... what is the routing for those, the way that I have it now leaves a few inches of spare wire. Spare wire always worries me.

2. The engine came with the belt sprocket on. How do you get that off without the belt holding it in place. Jam a block of wood into it and go nuts with the impact?

3. The engine did not come with the mounting lugs for the exhaust so I need to pull them out of my old head. (heh, lugs in my head. My wife has been right all along.) Those suckers aren't left hand thread or anything are they?

Thanks folks!

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