newgen engine in pregen bike?

ethen770 · August 18th, 2012, 10:12 AM

so i have a pregen 2001 250 and the engine blew in it. i got an epic deal on an engine but found out its a newgen. and i was wondering if it would set up in the frame? as far as i could tell the mounts were all the same. but just before i put all the work into taking out an entire engine i wanna make sure the new one is gunna fit. so basically what is the difference between the two?
thanks in advance
-Evan

csmith12 · August 18th, 2012, 10:21 AM

@RacerX is your man here.

Racer x · August 18th, 2012, 10:42 AM

i have not done that but the difference is the front mount and the issues with fairing mounts or radiator mounts. But the same as the other way around .

zzrguy · August 18th, 2012, 10:55 AM

Wiring harness im pretty sure is different is it not?

Racer x · August 18th, 2012, 11:18 AM

That is a surprise. The fan temp sensor in the radiator has a different plug . But the ignition and the charging system plugs are the same . You might have to change the oil pressure sensor also. But you can use the new gen one for the old engine.

r_1 · September 26th, 2012, 06:54 PM

2012 motor in 2005 frame. (Ebay Purchase w/269 miles!) front mount wider, exhaust connections different, stator connector different, oil pressure switch connector different. Used 2005 carbs with 1mm shims. Right front mount modified to clear head. Custom flanges for the exhaust welded to stock header shortned 1". Plugged EGR ports in head, billet cover where reed valve removed. Used 2005 sprocket cover which had to be cut (new one didn't come w/motor). Just changed the connectors for the stator and oil switch. The newer bikes seem to have a higher output stator (bigger wires/connector) I guess to allow for the extra headlight. Old motor broke cam chain, was purchased like this thinking would be easy fix. All rockers broke, both cams scored. Just the parts were more than the used motor and shipping. The new motors are shim under bucket, which should be more reliable if not nore of a PITA to adjust the valves. But it can be done.

Alex · September 26th, 2012, 08:05 PM

Nice work!

choneofakind · September 26th, 2012, 08:51 PM

nice! A higher output electrical system might explain why the newgen users who have done the efi conversion have no issues with power usage, but I do.

anyways, nice job on a motor swap!!

August 18th, 2012, 10:12 AM	#1
ethen770 ninjette.org newbie Name: Evan Location: Demorest Georgia Join Date: Nov 2011 Motorcycle(s): Ninja EX 250 Posts: 1	newgen engine in pregen bike? so i have a pregen 2001 250 and the engine blew in it. i got an epic deal on an engine but found out its a newgen. and i was wondering if it would set up in the frame? as far as i could tell the mounts were all the same. but just before i put all the work into taking out an entire engine i wanna make sure the new one is gunna fit. so basically what is the difference between the two? thanks in advance -Evan

August 18th, 2012, 10:21 AM	#2
csmith12 The Corner Whisperer Name: Chris (aka Reactor) Location: Northern KY Join Date: May 2011 Motorcycle(s): 2010 250 (track), 1992 250, 2006 R6 (street/track), 2008 R6 (track) Posts: Too much. MOTY 2015, MOTM - Nov '12, Nov '13	@RacerX is your man here. __________________________________________________ Goal: Shake A Million Hands \| Look through the corners \| Track Day Prep \| Closest track? \| The Mid-Ohio School

September 26th, 2012, 06:54 PM	#6
r_1 ninjette.org newbie Name: JR Location: Va Join Date: Sep 2012 Motorcycle(s): KTM,R1 Posts: 1	Just finished this for my son. 2012 motor in 2005 frame. (Ebay Purchase w/269 miles!) front mount wider, exhaust connections different, stator connector different, oil pressure switch connector different. Used 2005 carbs with 1mm shims. Right front mount modified to clear head. Custom flanges for the exhaust welded to stock header shortned 1". Plugged EGR ports in head, billet cover where reed valve removed. Used 2005 sprocket cover which had to be cut (new one didn't come w/motor). Just changed the connectors for the stator and oil switch. The newer bikes seem to have a higher output stator (bigger wires/connector) I guess to allow for the extra headlight. Old motor broke cam chain, was purchased like this thinking would be easy fix. All rockers broke, both cams scored. Just the parts were more than the used motor and shipping. The new motors are shim under bucket, which should be more reliable if not nore of a PITA to adjust the valves. But it can be done.

September 26th, 2012, 08:05 PM	#7
Alex ninjette.org dude Name: 1 guess :-) Location: SF Bay Area Join Date: Jun 2008 Motorcycle(s): '13 Ninja 300 (white, the fastest color!), '13 R1200RT, '14 CRF250L, '12 TT-R125LE Posts: Too much. Blog Entries: 7	Nice work! __________________________________________________ Montgomery Street Motorcycle Club / cal24.com / crf250l.org / ninjette.org ninjette.org Terms of Service Shopping for motorcycle parts or equipment? Come here first. The friendliest Ninja 250R/300/400 forum on the internet! (especially Unregistered)

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August 18th, 2012, 10:42 AM	#3
Racer x ninjette.org certified postwhore Name: Eric Location: Iowa City Join Date: May 2009 Motorcycle(s): 2008 Kawmeracchi 350 2010 Project X Posts: A lot. Blog Entries: 54 MOTM - Sep '18, Feb '16	i have not done that but the difference is the front mount and the issues with fairing mounts or radiator mounts. But the same as the other way around .

August 18th, 2012, 10:55 AM	#4
zzrguy ninjette.org member Name: Lostboy Location: Guelph Join Date: May 2011 Motorcycle(s): 2002 ZZR 250 Posts: 127	Wiring harness im pretty sure is different is it not?

August 18th, 2012, 11:18 AM	#5
Racer x ninjette.org certified postwhore Name: Eric Location: Iowa City Join Date: May 2009 Motorcycle(s): 2008 Kawmeracchi 350 2010 Project X Posts: A lot. Blog Entries: 54 MOTM - Sep '18, Feb '16	That is a surprise. The fan temp sensor in the radiator has a different plug . But the ignition and the charging system plugs are the same . You might have to change the oil pressure sensor also. But you can use the new gen one for the old engine.

September 26th, 2012, 08:51 PM	#8
choneofakind ninjette.org certified postwhore Name: . Location: . Join Date: Feb 2011 Motorcycle(s): . Posts: Too much. MOTM - Feb '13, Feb '14	nice! A higher output electrical system might explain why the newgen users who have done the efi conversion have no issues with power usage, but I do. anyways, nice job on a motor swap!!