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Wiring an older motor (Read 82 times)

Venturi

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Wiring an older motor
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.

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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28760 L.A. California Gender:	Re: Wiring an older motor Reply #1 - 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.
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Venturi YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 34	Re: Wiring an older motor Reply #2 - 01/31/20 at 07:38:58 Thanks Verslagen. Is that the only modification needed to get them working together?
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28760 L.A. California Gender:	Re: Wiring an older motor Reply #3 - 01/31/20 at 09:47:01 Venturi wrote on 01/31/20 at 07:38:58: 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.
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Venturi YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 34	Re: Wiring an older motor Reply #4 - 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?
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batman

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Re: Wiring an older motor
Reply #5 - 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.

my old work mates called me MacGyver

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Venturi YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 34	Re: Wiring an older motor Reply #6 - 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.
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batman Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 3806 osceola new york Gender:	Re: Wiring an older motor Reply #7 - 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)
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