1991 engine into a 2001+ frame

[BoomChuck]

has anyone tried to put an older GS engine into a 2001/2002 frame?  If so, how much of a pain in the ass is it to do? Can it even be done?  I'm contemplating putting my 1991 engine into a  2001 frame.  I'm not very mechanically inclined so this would be a huge project for me.

[dgyver]

89-02 are the same, save color and carbs.

04+ changed with the oil cooler and a deeper oil pan. Electricals are different as well.

[BoomChuck]

thanks dgyver! I'm pretty good at following directions, so I'll use the clymer manual to help me along.  How difficult do you think this would be to do? Should it not be attempted by anyone with no experience?  Is it such a pain that i would be much better off just paying a mechanic to do it?

[dgyver]

Not too difficult. It can be tricky to get the engine out, tight fit. I have done several by myself but would be easier with anothers help. The motor weighs about 140 pounds.

[Big Shot]

I've swapped out two motors so far.  It's a pain.  I'm not saying you shouldn't do it though, just don't get frustrated if you spend 10 minutes of time wrestling the thing around and you feel like you haven't gotten anywhere.  It probably will happen.  Few words of advice, bring a friend.  A mechanically inclined friend.  Unless you're masochistic...


You're gonna love my nuts - Bob!

[utgunslinger13]

only 140 lbs!  I pulled the engine and put it back in myself and HOLY SH!T I thought it weight 600000 lbs!  Listen to the advice, get an extra set of hands!

[joshr08]

gs motor is a cake walk try a katana 600 motor swap.  just pay attention where stuff was when you take it apart.

[utgunslinger13]

I'd recommed a new set of ziplock baggies and a sharpie.  As you take bolts out for one piece put them all together in the baggie and clearly mark them.  If your also concerned, I'd take 100's of pictures as you disassemble them to refer back to later.  Pay close attention to where wires are ran, and throttle/clutch cables, etc.

Nick

[BoomChuck]

great advice! thanks all.  I don't have a mechanically inclined friend but I will invite someone over to help me move that 600,000 pound motor, uh er 140!

[utgunslinger13]

600,000, or 140....Its heavy as hell doing it by yourself lol

[5thAve]

Yeah, it's not hard. Just heavy. I used a jack and went really slow and careful like! Got it out on my own. I'm smart enough that I'll recruit a friend to help put it back in !!  I won't be trying that with just my two hands.


Everything disconnected, subframe member removed, and just about to take out the last of 4 mounting bolts to "drop" the engine. (Please drop yours gently).


[edit] Just a footnote: I thought I had disconnected all the wires and cables (followed the manual, after all) but had to scramble as I was lowering my engine when I discovered the ground wire was still connected. It's hidden away kinda at the back, and you have to pull one of the case bolts to remove the wire. It's hard to see and doubly hard to do when the engine is already free of the frame, balance precariously on a wobbly jack, held in place by one hand, one toe and a prayer, and all your wrenches are on the far side of the garage. I'm just sayin'....   

[utgunslinger13]

HAHAHA I FORGOT ABOUT THAT GROUND WIRE!  Screwed me up big time!