03 engine in 04bike

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Joined
Sep 21, 2009
Messages
30
what are the complications? what else would i need in regard ignition or any electrical bits and bobs thanks
 
I've put a 2002 engine in my 2008 chassis when the 2008 engine selfdestructed. Engine fits right in, you need to swap the cdi also, since the 2003 uses the SEM ignition and the 2004 uses the kokusan brand ignition.

You can use one of the two yellow wires (these are uses for lights, horn,... on the 2003 chassis) wich come from the SEM stator to power the stock wiring loom for the newer chassis.
I've also swapped over the voltage regulator from the 2002 bike to power the lights on the 2008 chassis, couldn't get it to work through the stock 2008 regulator.

If you have a blown up motor, make sure you swap the 2004 carb, side cover and kickstarter over to the older bike.

If you have more questions, let me know!
 
adam123 said:
hi mate thanks for the reply to my 03 engine into 04 bike thread, i blew up a 450 and im putting in a 650, so im assuming swappin the carb is no good, also exhaust system is there a difference at all? so what will i need to do to my 04 loom? thanks

Don't know about the carb, could be that the 450's used a smaller bore carb, someone here will give you an answer on that. Who knows the smaller FCR carb might even be better than the bigger old mikuni round slide carb???

Nothing you have to do to you wiring loom, just connect one of the yellow wires coming of the SEM stator to the correct connector on the 2004 rectifier and everything will work except the lights.
Connect the second yellow wire to your 2003 voltage regulator (square box, hole in center, two wires coming out) and connect that to the lights on the 2004.

The 2004 rectifier will turn the 60V ac current (that's what the SEM igintion delivers) into 12V dc current to power the dash, starter, charge battery,...
The 2003 voltager regulator will turn the 60V ac current into 12v ac current for the lights. Whatever you do, make sure you don't mess up and put ac current into parts that need DC current, that will mess them up!!
 

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