2008 GS500. Trying to fit a 2002 engine. What modifications?

[slidy500]

Hi guys as stated I am trying to fit a 2002 engine into my 08 bike due to valve failure essentially. I have the engine but the wires are different etc and I just need to know what mods need to be done to get it running

[chris900f]

The 2004+ bikes, with TPS use a different (6-lobe)ignition rotor. I don't know if the pick-up is the same or not.

You need to pull the 2008's ignition rotor (and pick-up?) and install it in the 2002 engine. This will give you the TPS, electronic tach, and the air-solenoid signal for the carbs--it's also a much easier job than replacing the harness and ECU

cheers.

[Armandorf]

Pickups are different, 1 coil pickup for 2004+ model.
2 pickup for older model, less lobes on the rotor.

TCM/CDI is different. newer one has more wires, including the connection for the TPS sensor on newer carbs and the PAIR solenoid for some models(messes with vaccum and diafragms, a hoses hell.


You can put the old rotor(2pickups) with old wiring in the new crankshaft.
New carburetor no problem, just unplug extras.

New rotor=new CDI/TCM and new wiring

Other things are the same between wirings, starter relay changes style, older is round and newer has 4 pins but is the same electrically though not plug and play, they are cheap generic ones like for a honda cbx250 for easy replacement.

Sidestand relay is exactly the same.
New wiring has the spark signal routed for electronic tach. older doesnt as chris900f stated.


 

You need to pull the 2008's ignition rotor (and pick-up?) and install it in the 2002 engine.

exactly this, pickups and rotor and you are done