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Issues replacing 1996 engine with 2003? (Read 87 times)

BuckRYCA Senior Member Offline Posts: 258 New London, CT, USA Gender:	Issues replacing 1996 engine with 2003? 06/02/12 at 21:09:58 Transmission main shaft splines are gone after 22K miles on my 1996 Savage. Looking at 2003 Savage with 1500 miles for not much more than cost of transmission repair. Any known compatibility issues with engine swap?
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28886 L.A. California Gender:	Re: Issues replacing 1996 engine with 2003? Reply #1 - 06/02/12 at 21:24:49 should be a direct swap, no known issues at all.
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Serowbot YaBB Moderator ModSquad Offline OK.... so what's the speed of dark? Posts: 28657 Tucson Az Gender:	Re: Issues replacing 1996 engine with 2003? Reply #2 - 06/03/12 at 01:26:59 verslagen1 wrote on 06/02/12 at 21:24:49: should be a direct swap, no known issues at all. Yarp... ...
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Re: Issues replacing 1996 engine with 2003?
Reply #3 - 06/03/12 at 07:38:28

Getting the other bike also gives you a spare parts source too.

However, I'm curious as to why these splines would have stripped out so soon (or at all, for that matter)? Isn't the drive pulley a fairly tight fit on the drive shaft? I would think that play between these components would be a bad thing. That just seems strange to me. Savvy Savage motor guys, comment here?

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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28886 L.A. California Gender:	Re: Issues replacing 1996 engine with 2003? Reply #4 - 06/03/12 at 07:53:15 You'd have to press the pulley on to have no play at all. The power pulses of the savage just tear these splines apart.
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Re: Issues replacing 1996 engine with 2003?
Reply #5 - 06/03/12 at 08:31:07

I know it's not a pressed fit, but any "clank" would be bad too, especially given these components transmit the thumpy power directly to the rear wheel. I would imagine the tolerance being a few thousands, at most.

In any case, 22k doesn't seem the usual service life of this component, or at least, I sure hope not! The other thing is, if Zuk anticipated early failure, I would hope that the pulley itself would have been made of slightly milder steel so that it wore out before the drive shaft as it's easier to replace.

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BuckRYCA Senior Member Offline Posts: 258 New London, CT, USA Gender:	Re: Issues replacing 1996 engine with 2003? Reply #6 - 06/03/12 at 17:06:24 Thanks for the replies. I think I'm going to buy the 2003 and do the swap. 22K miles is too soon. Details of my sad story are here: http://suzukisavage.com/cgi-bin/YaBB.pl?num=1338525938/15#15 Lesson learned is that a torque check on the front drive pulley retaining nut is a 4K miles maintenance item.
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