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Old April 30th, 2018, 05:58 PM   #1
Bdjones3565
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Name: David
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New engine

Can you install a 2010 250r engine in a 2000 250r chassis?
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Old April 30th, 2018, 10:12 PM   #2
DannoXYZ
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MOTY - 2018, MOTM - Nov '17
Hi and welcome!

Yes it can be done. Some fabrication, cutting & welding needed.

- use newgen front motor mounts. Needs a little cutting and narrowing
- newgen radiator as it connects to front motor mounts
- newgen coolant pipe where it connects to head
- newgen exhaust. Have to fabricate hanger bracket for muffler
- newgen carbs. Jetting and flow-rates are completely different.
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Old May 3rd, 2018, 06:56 PM   #3
choneofakind
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Quote:
Originally Posted by DannoXYZ View Post
Hi and welcome!

Yes it can be done. Some fabrication, cutting & welding needed.

- use newgen front motor mounts. Needs a little cutting and narrowing
- newgen radiator as it connects to front motor mounts
- newgen coolant pipe where it connects to head
- newgen exhaust. Have to fabricate hanger bracket for muffler
- newgen carbs. Jetting and flow-rates are completely different.
I've done it. A little more info


- use one newgen mount, one pregen mount. This allows you run run the pregen radiator with minimal brackets needed to locate the pregen radiator on the newgen mount, but also gets the width needed. It's bolt up.
- drill the spot weld on the pregen coil bracket to separate it from the engine mount. These will bolt up still.
- Newgen radiator straight up WILL NOT fit with pregen body work without modification of said body work. That's why I used one engine mount from each generation and fabbed brackets for the newgen side to mate with the pregen radiator. More thinking now and I think I used the newgen mount on the right side.
- newgen exhaust. Use aftermarket so you have more flexibility in the mount. Aftermarket has a band clamp. Factory has a hard mount. Aftermarket fits right up easily.
- jetting is necessary, but it's easy enough. It's just jetting. I had the pregen air box, new gen engine, newgen exhaust. I think I settled on Keihin 108 mains and then tweaked needle height and idle jet to work. It's in the jetting thread, ball park septemtber 2017.
- pregen chin fairing does not fit with aftermarket newgen headers.
- newgen spark plug boots! This is important. Pregen spark plug boots don't get captured in the newgen valve cover gasket properly. Buy a set of newgen plugs/wires, pull them apart, and make some frankenstein leads (super easy) with pregen coils, pregen wires, and newgen boots. Super easy. Very reliable. no issues here.

No welding the way I did it. Minimal fab of basic brackets. Minimal cutting/drilling of parts to make them work. Easy peasy. But it took me entirely too long because I wasn't motivated and I was busy AF with my job at the time. If you're motivated and prepared and familiar/skilled, you can have this done in a weekend. Compared to car engine swaps from scratch, this one is nearly bolt on.
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Old May 3rd, 2018, 08:50 PM   #4
Bdjones3565
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Name: David
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Re: New Engine

Thank you both for the how to's.
I will keep you posted on the progress.

Cheers David
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