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
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 :cool:
cheers.
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.
Quote from: chris900f on April 15, 2024, 12:12:01 AMYou 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