Engine swap completed - 04F to 99E - report (some unsolved problems)

[nikux]

Last weekend I was finally able to complete the engine swap from 2004F to 1999E. I probably had a spun bearing (still have to open the bottom part to satisfy my curiosity) and decided to go with the engine swap. Firstly it IS possible to swap engines from different models. There are some differences which i talk about later.

So... got an engine from LA with 20k miles for $260 with oil cooler.

The first task was taking the old engine out. It was a laborious process but nothing very technical. I used some bricks and a car jack to support the engine from bottom and had two thick adjustable nylon straps with hooks that I used to support the engine from top. Basically the hooks went onto the motorcycle frame and the nylon straps around the engine from below. The hardest part was making sure that the engine does not get stuck from different places. I removed the valve cover for convenience.
[Quick Tip] loosen all the engine mounting bolts before taking the bolts out. Especially the two long back bolts. The manual says to loosen them at last, but with all the weight on those two bolts it was tough to loosen them.

Installing the second engine was almost as difficult as taking it out. The problem is that left side generator cover always gets stuck. At first it just did not go in. Tired I finally decide to remove the generator cover. To do so I had to lower the engine, somehow the angle was right and poof went in the generator cover on to the left side of the frame. Rest was easy.

Now the 04 engine differs from the 99 engine in these respects:
1. Ignition rotor (right side)
Thats #3 and #4 on the signal generator figure (see http://gstwins.com/gsboard/index.php?topic=40963.msg460327#msg460327)
Solution: Just use your old rotor and generator assemble, and done. This is what is changed.



2. Generator wires.
I dont know if this is true for all 99 models but  my generator leads (three yellow colored leads) had a different connector than the 04 engine. Luckily the three wires were connected to the regulator/rectifier on the right side using the same plastic connector as the new 04 generator. So just re-routed the wires.



3. Battery Lead
Nothing much, the lead was different (I used starter motor from the new engine), used the old one.

4. Oil Cooler. (*UNSOLVED*)
Now this is one problem I am still not able to solve. Basically if I want to use the oil cooler with the new engine I dont have the mounting holes on my frame. There are three holes on the frame where the oil cooler is supposed to be mounted. Two of them are used for the horn and one to mount the support hook for the wires. I removed the horn and the support ring. The oil cooler can use one of those holes - the hole for support ring, but there is no hole for the other bolt. (see figure). Also once the cooler is on, there is no space for horn. I see that the 04 model has an extension to mount the horn but that extension does not work with 99 model. Right now I have mounted the cooler with just one bolt, and have taped the horn on the side. Any suggestions?



5. Tachometer (*UNSOLVED*)
Electric tachometer replaces the mechanical unit of 99.
I guess the only solution is to use a new aftermarket electric tachometer. Any suggestions on where to buy one and what model?

All in all it was well weekends spend. It great to see my motorcycle up again after a months hiatus for another long trip. This time I will make sure to add oil on time.

[nightrider]

Nice work Nikux! Not many people are up to an engine change, you did it. I usually just change my oil or something and write up a page about it with bullet points. Props! 

Nice engine!!! Such a recent year, in such good condition, and for an amazingly low price... there are still good people left in the world. 

[Jay_wolf]

THe tach is just a wire wrapped round the ht coil

Acewells are good , but if u get a 04+ tach  and put it in the old cluster . im sure it would be fine

[The Buddha]

Oooooo ... the new trigger plate only has 1 pickup coil ... maybe that's why the advancer has extra nubbies ... or atleast 1 of them is for the engine speed sensor for the carb, and 1 for the tach (unless they are shared) ... I wonder if it can be advanced the same way the 89 -00 is done. The large nub is the dwell, and the under side is likely to the the same type as the old one. So we should be able to drill it for the locating pin just off the old spot like Bob does an 89-00, and trim the large nub to modify the rpm reading the BB gets.
Cool.
Buddha.

[dgyver]

5. Tachometer (*UNSOLVED*)
Electric tachometer replaces the mechanical unit of 99.
I guess the only solution is to use a new aftermarket electric tachometer. Any suggestions on where to buy one and what model?

I thought the 04 still had the hole in the head for the tach drive gear. It shows a plug in the parts diagram. Not sure about the exhaust cam having the worm gear though. I have several drive gears if you could use one.

[coll0412]

You could also buy a 02+ Tachometer and Speedometer. They are the same as the previous years expect the tach is electric instead of mechanical.

[The Buddha]

5. Tachometer (*UNSOLVED*)
Electric tachometer replaces the mechanical unit of 99.
I guess the only solution is to use a new aftermarket electric tachometer. Any suggestions on where to buy one and what model?

I thought the 04 still had the hole in the head for the tach drive gear. It shows a plug in the parts diagram. Not sure about the exhaust cam having the worm gear though. I have several drive gears if you could use one.

It has that plug ... how about the worm gears and the helix on the cam shaft ...
Stupid suzuki ... remove the tach drive mechanism but leave all crap in place ... does it still leak oil frrm there ... just great suz clowns ... now another thought - does any other bike use a GS500 head
Cool.
Buddha.

[dgyver]

You could also buy a 02+ Tachometer and Speedometer. They are the same as the previous years expect the tach is electric instead of mechanical.

89-02 are mechanical
04+ are electric

[2thExcavator]

I'm putting 05 motor in my 92.  Thanks for putting up the wiring stuff cause I'm about to that point.   

I tapped the same hole you did thats supposed to be for the horn.  As for the horn, mount it up inside the frame in the front.  Just behind the neck of the frame there is some trussing and so forth.  Should be pretty easy to find a home for it up under there.  The oil cooler is pretty well set as to where it can be (aside from making new plumbing) but the horn is pretty flexible. 

[RoblesGT]

i recently blew the motor on my 05 gs500 ... same oil thing ... its my first bike, bought it used, and i had no idea it ate the oil ...

anyway, i'm looking into getting either a motor alone or an older bike and swap the engine ... right now i'm looking at a 96 motor ... you guys think this is possible ??  95 gs500 motor into a 2005 ??

[nikux]

i recently blew the motor on my 05 gs500 ... same oil thing ... its my first bike, bought it used, and i had no idea it ate the oil ...

anyway, i'm looking into getting either a motor alone or an older bike and swap the engine ... right now i'm looking at a 96 motor ... you guys think this is possible ??  95 gs500 motor into a 2005 ??

Yes its possible, two things though
1. You will have to do away with your fairings. The 95 motor will not have a oil cooler and the fairing will not allow for proper cooling.
2. You wont be able to use your Tach. The only option is to buy a mechanical tach (older models).

Apart from that,
You might need some extra wires (atleast my 99 generator had different connections from the 04)
You will need to use the ignition rotor and pickups from your 05 motor.