I found a 2004 engine and was wondering if I could get it to swap into a '95 frame and electronics.  Will it work?  I have a feeling the electronics won't matchup because of the emissions.  anyone oever done this?

It'll match up.. BUT, you'll need a new tach, since they're electric on the '04+. Also, you'll have to find some way to mount up the oil cooler, since your frame won't have the tabs for it. Beyond that, it should be a bolt in.

the oil cooler is no problem.  I'm a welder.  But, do I have to get any new electronics other than the tach.  The generator, starter, coils and everything are the same then?  If that is the case I am on my way to a newer motor.  This one is shot and I just don't want to rebuild it.  I wonder if I can run without the oil cooler since I won't have fairings on.  Oh, do you think the original carbs for the 95 will work fine?

You'll need new carbs from an '01+. Aside from carbs and Tach, I can't think of anything else you'll need. However, wait for one of the gurus to chime in. Or run a search, this has been covered before, I'm pretty sure.

Just a bump to try and see if anyone else has info on this for me

Don't forget that the newer GS's (04+?) now have a TPS for ignition timing.  Mine also had what appeared to be a MAP sensor that I noticed when I jetted the carbs.

-Turd.

You wont need a TPS or 01+ carbs if you swap out the iginition componets with your old one. Other that the addition of the oil cooler and whatever they did with the tach drive its identical. It is really simple to replace to swap the ignition on the right side crankcase. The oil cooler mounting should also be pretty straight foreward.

That is what I thought I just wasn't sure because I haven't played with these machines much yet.  I'm starting to understand that it is REALLY basic.  I'm used to my zzr.  This thing is easy to wrench on!!  Thanks for all the help guys.  I'm on my way to a motor with less than 4000 miles on it.  Woohoo!!

Alex

Quote from: Turd Ferguson on October 15, 2006, 12:51:51 PM
Don't forget that the newer GS's (04+?) now have a TPS for ignition timing.  Mine also had what appeared to be a MAP sensor that I noticed when I jetted the carbs.

-Turd.

Why does he need new carbs? Old ones should fit indentically to the new ones.

There is a TPS on the new carbs that needs to be hooked up?

I think if I stick with the old carbs the engine will run just like a 89-00 model.  the engine itself never changed just the carbs and electronics.  I think the engine will work just fine if I plug in all the 95 electronics I have.  After all, none of the electronics "control" the engine other than the ignition and I can switch that over to the 89-00 version with a couple of bolts.  The mounts are the same.  I think this is going to work.  I will let you all know. 

You also need to swap out the all the crank position sensor components.  The 04'+ use 1 VR sensor and a 4+1 tooth wheel (IIRC) on the crank for ignition timing, while the '89-'02 use 2 VR sensors and a 2 tooth wheel.