1 Good engine out of 2

Petorius · Apr 28, 2011

Probably should not have done it but bought what i am told is a good '03 650 engine to replace my blown 650 '04. I suspect that the Kokusan ignition from the old engine will not fit the '03 engine from bits i have read on here.
If it is possible i would like to fit the later ignition.

Also i was wondering if there are any other parts that it would be a good idea to reclaim from the 04 engine. The '04 dropped a valve.

Many thanks

Mark

BelgiqueBasterd · Apr 28, 2011

Why not keep the 04 engine, ignition, gearbox,etc and swap the parts from the 03 into the 04? Dropped a valve so what is broken? Head, sleeve, piston and even the cam (check the doc to be sure) can be swapped over.

If there is no damage try and keep the tappets from the 2004 as they have better bearings than the 2003. As for the the balancer try and get an 08 wich had much better bearings than the 03/04 ones.

03 to 04 had some major changes like the carb, ignition and much more check the doc for details.

Petorius · Apr 28, 2011

Thanks Belgique,
The piston is trashed and the liner too. I suspect the con rod is bent as well. The head is damaged but usable.I take your point about the rockers, these seem okay and will probably replace them as you suggest.
I was going to fit the Kehein carb from the 04 to it and had hoped to fit the ignition but from what i have read it may not be possible. Other than that i was just going to fit the engine cover as it has clutch access.

BelgiqueBasterd · Apr 28, 2011

Still don't understand why you don't swap the parts from the 03 on the 04? That way you can keep the kokusan ignition.

swedishsteel · Apr 28, 2011

BelgiqueBasterd said:
Still don't understand why you don't swap the parts from the 03 on the 04? That way you can keep the kokusan ignition.

1+

zaga · Apr 29, 2011

Hi Petorius

Save your self lots of headache and use the 04 egine as your work base.
By doing that you will solve the two major problems of the pre-04 engines, i.e. dellorto carb and SEM ignition.

Specialy with the ignition you will be thanking us for this advice for the rest of your life :!: :!:

:cheers:
ZAGA

Petorius · May 5, 2011

Thanks chaps, just seems a shame to pull apart what i am told is a perfectly good engine. I have a delorto carb with it and a spare SEM stator.
I will give it some more thought, bit of a money pit this bike and difficult to know where to draw the line when it comes to spending money.

zaga · May 5, 2011

Hi Pretorius

I don't know the 650 engine, if the modifications are the same as 400, but its not just the ignition, you should have a lot of better things in the 04 engine, that I have changed in my 02 engine.

You have the FCR carb, the 08 cam, the new automatic decompression cam, the timming chain tensioner, etc. All those things that are major improvements over the older engine.

Probably you have things that you can use as spares for both engines and parts that you can sell, like the SEM ignitions and stators, etc.

Or you can just keep both... its just $$$$ .. :mrgreen:

:cheers:
ZAGA

1 Good engine out of 2

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