Swap Old Engine into Newer SV? - SV650.org

21-09-06, 02:41 AM

Has anyone here had experience with swapping an older lump ('99 - '02) into the newer chassis ('03 - '06) SV650?

Racing this year I’ve blown two newer style motors (snapped crankshafts, ruined engine cases, etc.) and I want to be sure the older style engine will fit if I happen to come across a good one. Been told the older cranks and engine cases are stronger.

By searching this site I found one post indicating that to fit a newer lump into the old chassis you would use the following parts from the old lump to make the new one work with the carbs.

Generator and rotor (different size)
Gear-position indicator (Reads every gear for injection)
inlet rubbers (different size and angle)
Thermostat housing (temp sender is different)

Assume the opposite would be true to get the old motor to work with the fuel injection. I’ll also be swapping in the cams, pistons, cylinders, heads, etc. from my old race motor.

Any thoughts greatly appreciated.

TSM · 21-09-06, 07:55 AM

If you just put in a CDI & loom from a 1st gen bike then it should work easier.

Viney · 21-09-06, 08:00 AM

Wont the crank fit from the earlier engine?

As for engine casings. Get some armour www.bikejohnny.com

21-09-06, 08:02 AM

Quote:

Originally Posted by wmrra#30

By searching this site I found one post indicating that to fit a newer lump into the old chassis you would use the following parts from the old lump to make the new one work with the carbs.

Generator and rotor (different size)
Gear-position indicator (Reads every gear for injection)
inlet rubbers (different size and angle)
Thermostat housing (temp sender is different)

Assume the opposite would be true to get the old motor to work with the fuel injection. I’ll also be swapping in the cams, pistons, cylinders, heads, etc. from my old race motor.

Haven't tried it that way round but have put fuel injected engines in to the old frame. The only thing we changed were the inlet rubbers and the generator and rotor (including the engine casing on that side). Everything else just worked.

Would suggest you keep the barrels, cylinders, etc. as they are and just swap the cams, tensioners and buckets. Anything else is a waste. Alternatively just get a K5 fuel injected motor as I have yet to hear of one breaking a crank which seems to happen most frequently in the K3 motor.

21-09-06, 08:05 AM

Quote:

Originally Posted by wmrra#30

Generator and rotor (different size)

It's not that they are a different size it's that the fuel injected bike has loads of pick ups on the fly wheel where as the easrly motors only had one.

northwind · 21-09-06, 11:10 AM

Out of curiosity, what have you got on top of that bottom end?

21-09-06, 02:41 AM	#1
wmrra#30 Guest Posts: n/a	Swap Old Engine into Newer SV? Has anyone here had experience with swapping an older lump ('99 - '02) into the newer chassis ('03 - '06) SV650? Racing this year I’ve blown two newer style motors (snapped crankshafts, ruined engine cases, etc.) and I want to be sure the older style engine will fit if I happen to come across a good one. Been told the older cranks and engine cases are stronger. By searching this site I found one post indicating that to fit a newer lump into the old chassis you would use the following parts from the old lump to make the new one work with the carbs. Generator and rotor (different size) Gear-position indicator (Reads every gear for injection) inlet rubbers (different size and angle) Thermostat housing (temp sender is different) Assume the opposite would be true to get the old motor to work with the fuel injection. I’ll also be swapping in the cams, pistons, cylinders, heads, etc. from my old race motor. Any thoughts greatly appreciated.

21-09-06, 07:55 AM	#2
TSM The Sick Man Mega Poster Join Date: Nov 2004 Location: Peckham.SE.LDN Posts: 4,768	If you just put in a CDI & loom from a 1st gen bike then it should work easier. __________________ OTR: KTM 690 Duke R 2015 Full Akro SIDELINE: Kwak ZX636 A1P 2002, Red, R&G's, Yoshi, Double Bubble Screen GONE: Kwak ZX-7R P1, Full Akro, Undertray, Screen GONE: SV650S K2 Very Bruised & Without Fairing, Motovation Frame Sliders, R&G Ally Sprocket Toe Protector, HEL 2 Line Setup, GSXR K1 600 RWU Forks, Barnett Clutch & Springs, Penske 8981 Shock, Gilles Ti Rearsets, Steel Barends, Scottoiler, AFAM Chain & Sprockets, Twin FIAMM Horns, Skidmarx Bellypan, Full Micron Zeta Steel System, Cut down undertay. Forum Problems & Information / Site Suggestions

21-09-06, 11:10 AM	#6
northwind Moderator Mega Poster Join Date: Jan 2004 Location: In the garage where I belong Posts: 17,083	Out of curiosity, what have you got on top of that bottom end? __________________ "We are the angry mob, we read the papers every day We like what we like, we hate what we hate But we're oh so easily swayed"

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21-09-06, 08:00 AM	#3
Viney Member Mega Poster Join Date: Jul 2003 Location: In the shadows to the left Posts: 7,700	Wont the crank fit from the earlier engine? As for engine casings. Get some armour www.bikejohnny.com