I, as you all know, have an 07 with a really bad engine knock. I found an 02 complete bike for sale $750. Engine on the bike appears to be running fine. I'm considering buying the 02, using the engine and parting ot the rest of the bike. Other option is to crack into my engine, find what's wrong with mine and get the parts from the 02. Here's the big question: what are the issues in using the 02 completely. From what I understand only the added oil cooler is different. Not having that on the 02, what are the issues with that? Can my oil cooler from the 07 be added to the 02?

Can't use the oil cooler unless you do some modification inside the motor.  An oil passage restriction or something.  I think it could be done, but I don't know.

Electrical is different from 89-02 and 04+. Have to use the signal generator & rotor from the 07 on the 02. Oil cooler will not work, there is additioinal plumbling cast into the 04+ cases. The tach drive on the 02 will be exposed. Not a real big deal, it can be left alone or plugged with parts from an 04 (tach drive port removed in 05). I have gutted the drives before on track bikes and plugged them with a bolt and silicone.

I plan on using just the engine itself from the 02 and switching everything from the 07 to it. Engine swap a hard thing to do?

Pain in the arse to swap an engine by yourself, heavy and tricky to get it out of the frame without scratching it up. Get some help, an extra set of hands is very helpful. Overall it is not tough.

I've dropped the engine, and put it back in myself and let me offer this piece of advice.

IT SUCKS TO DO IT ALONE.  Get friends, buy beer, and use their muscles to help get it back it.  Be prepared to scratch up the frame/engine cases getting it back in, unless you strip the engine down (remove the head/cylinders) and install the case only.

A good frame protecting trick while doing engine removal/installation is to take an old garden hose and slice it down one side. Wrap your frame with it and tape it up.

Quote from: scroggins5000 on May 24, 2010, 09:52:00 AM
A good frame protecting trick while doing engine removal/installation is to take an old garden hose and slice it down one side. Wrap your frame with it and tape it up.

HAHAH NICE!  I never thought of something like that!

You already own an engine, the one thats on there now and it costs nothing but time to take it apart.  I'd get some zip lock bags and markers to organize stuff from different areas of the bike.  Personally I'd rather try to find a crashed 04+ for the engine, I'd like to retain the cooler and have to chance over as few parts as possible, you may be able to salvage some other parts to recoupe some money.  Its probably a good idea that you have a mechanic friend watch you when you start taking apart the insides of your engine.  Good luck with your summer project!