next-gen engine installed in 03 - DONE

rickthefix · October 23rd, 2012, 06:14 PM

I have successfully installed an 08 engine & exhaust in my 03. It was a little challenging, but not as bad as some of you made it out to be.
Had to remove the center stand for the 2-1 to fit. had to cut the the right mount n weld on a plate to outer side n welded on a nut. put a cap on the head vent. the engine i bought also came with a set of ignition coils n they are shorter, added a little strap to fill the span. also came with a carb set that was VERY clean so has the correct jetting.
only thing left is to buy n replace 2 coolant line 0-rings n wait for a battery i bought off ebay (AGM) to get here, but the one that came in the bike is good enough to jump off & took it for a test ride today in neighborhood.
Another thing is the lower fairing is no going to get installed cause the 08 exhaust would be too close & prob melt it.
I still have a couple correct engines in process of rebuild. One is to point of lapping valves & reassembly of head & then install head. Have 2 bottom ends to work with to get 1 for other engine to rebuild, but it may take a bit longer to get to that.

rickthefix · October 23rd, 2012, 06:16 PM

This is it with the fairing just sort of hanging there

alex.s · October 23rd, 2012, 06:23 PM

Cool. Can you take a photo of the cut and repositioned top engine mount you are talking about? How far did you have to move it? Did you try using the new gen top frame mounts?

rickthefix · October 23rd, 2012, 06:41 PM

All i did was cut off the threaded bung on the top right mount, weld a steel plate to the outside face of the mount, drill a hole in the right spot & weld a nut on. Also had to order the mounting bolt since the 03 bolt was too short.
I didn't have the next-gen mount & found another pre-gen set on ebay for $16 delivered that I used, didn't want to destroy my original set since I'll need them to run the rebuild engines. Not sure if I'll leave the next-gen engine in it or go with one of the rebuilds when done............ decisions, decisions. haha

Motofool · October 23rd, 2012, 06:52 PM

Quote:

Originally Posted by rickthefix

I have successfully installed an 08 engine & exhaust in my 03......

Perfect solution for a naked pre-gen; thanks !!

Eagle981 · October 24th, 2012, 04:38 PM

Looks good. Makes me wonder if someone will put a 300 engine into a pregen.

CZroe · October 25th, 2012, 02:08 PM

I wonder if the countershaft sprocket alignment is off by a mm or two considering that it changed slightly between generations.

TonyKZ1 · March 20th, 2013, 08:55 AM

I realize that this is an old post, and you've since replaced the 08 engine with a pre-gen one. And you've put the 08 engine & parts up for sale. But how well did it work out, comparisons between the two engines? Or was there not much difference between them?
Thanks, Tony

rickthefix · March 20th, 2013, 04:56 PM

I could not really tell any difference in performance, maybe just a little less umph out of tight turns. But could have just been knowing there might be a difference. But then there's mind-over-matter, you know, if you don't mind, then it don't matter

October 23rd, 2012, 06:14 PM	#1
rickthefix Crashing sux Name: Rick Location: N. Ga Join Date: Sep 2012 Motorcycle(s): 07 EX250, 04 ZX6R, 96 Vulcan EN500, 79 XS650-SF, 80 TS185 Posts: 62	next-gen engine installed in 03 - DONE I have successfully installed an 08 engine & exhaust in my 03. It was a little challenging, but not as bad as some of you made it out to be. Had to remove the center stand for the 2-1 to fit. had to cut the the right mount n weld on a plate to outer side n welded on a nut. put a cap on the head vent. the engine i bought also came with a set of ignition coils n they are shorter, added a little strap to fill the span. also came with a carb set that was VERY clean so has the correct jetting. only thing left is to buy n replace 2 coolant line 0-rings n wait for a battery i bought off ebay (AGM) to get here, but the one that came in the bike is good enough to jump off & took it for a test ride today in neighborhood. Another thing is the lower fairing is no going to get installed cause the 08 exhaust would be too close & prob melt it. I still have a couple correct engines in process of rebuild. One is to point of lapping valves & reassembly of head & then install head. Have 2 bottom ends to work with to get 1 for other engine to rebuild, but it may take a bit longer to get to that.

October 23rd, 2012, 06:23 PM	#3
alex.s wat Name: wat Location: tustin/long beach Join Date: Sep 2009 Motorcycle(s): wat Posts: Too much. Blog Entries: 5 MOTM - Oct '12, Feb '14	Cool. Can you take a photo of the cut and repositioned top engine mount you are talking about? How far did you have to move it? Did you try using the new gen top frame mounts? __________________________________________________

March 20th, 2013, 08:55 AM	#8
TonyKZ1 ninjette.org member Name: Anthony Location: Marble Hill, MO Join Date: Dec 2008 Motorcycle(s): 1975 Kawasaki KZ400D (Sold), 1989 Kawasaki Ninja 250 (sold), 1997 Yamaha XJ600s Seca II Posts: 231	I realize that this is an old post, and you've since replaced the 08 engine with a pre-gen one. And you've put the 08 engine & parts up for sale. But how well did it work out, comparisons between the two engines? Or was there not much difference between them? Thanks, Tony __________________________________________________ 1997 Yamaha Seca II - mostly stock, Racetech upgraded forks, FZ6R rear shock, Oxford Heated Grips, Barkbusters Blizzard Handguards, a Scottoiler vSystem chain oiler. My Mileage Tracker Page.

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October 23rd, 2012, 06:41 PM	#4
rickthefix Crashing sux Name: Rick Location: N. Ga Join Date: Sep 2012 Motorcycle(s): 07 EX250, 04 ZX6R, 96 Vulcan EN500, 79 XS650-SF, 80 TS185 Posts: 62	All i did was cut off the threaded bung on the top right mount, weld a steel plate to the outside face of the mount, drill a hole in the right spot & weld a nut on. Also had to order the mounting bolt since the 03 bolt was too short. I didn't have the next-gen mount & found another pre-gen set on ebay for $16 delivered that I used, didn't want to destroy my original set since I'll need them to run the rebuild engines. Not sure if I'll leave the next-gen engine in it or go with one of the rebuilds when done............ decisions, decisions. haha

October 24th, 2012, 04:38 PM	#6
Eagle981 ninjette.org member Name: Guy Location: Arizona Join Date: Sep 2012 Motorcycle(s): 2007 Ninja 250R Posts: 57	Looks good. Makes me wonder if someone will put a 300 engine into a pregen.

October 25th, 2012, 02:08 PM	#7
CZroe CPT Falcon Name: J.Emmett Turner Location: Newnan, GA Join Date: Apr 2009 Motorcycle(s): '08 CP Blue EX250J, '97 unpainted EX250F, 2nd '97 unpainted EX250F (no engine), '07 black EX250F Posts: A lot.	I wonder if the countershaft sprocket alignment is off by a mm or two considering that it changed slightly between generations.

March 20th, 2013, 04:56 PM	#9
rickthefix Crashing sux Name: Rick Location: N. Ga Join Date: Sep 2012 Motorcycle(s): 07 EX250, 04 ZX6R, 96 Vulcan EN500, 79 XS650-SF, 80 TS185 Posts: 62	I could not really tell any difference in performance, maybe just a little less umph out of tight turns. But could have just been knowing there might be a difference. But then there's mind-over-matter, you know, if you don't mind, then it don't matter