Gen 2 motor conversion on Gen 1

[adrenalinejunkie]

Anyone have tips on putting a Gen II motor and dash into a Gen I?

[sportbikeryder]

Headlight harness and controls are also different. Best bet to get full motor, harness, controls, airbox, etc. Will also need to do somethign with the fuel pump connector and mount the dash.

[adrenalinejunkie]

Any mods to mounting the dash?

[adrenalinejunkie]

What kind of fuel pump setup should be used?

Motor will be stock, but down the road may go with motor mods or turbo. Would be nice to run same pump setup if possible.

[sportbikeryder]

What kind of fuel pump setup should be used?

Motor will be stock, but down the road may go with motor mods or turbo. Would be nice to run same pump setup if possible.

I'd just put a bosch or walbro in-tank in it. WOn;t really be great for a future turbo. But would still be fine for motor mods or some spray. 

[adrenalinejunkie]

What kind of fuel pump setup should be used?

Motor will be stock, but down the road may go with motor mods or turbo. Would be nice to run same pump setup if possible.

I'd just put a bosch or walbro in-tank in it. WOn;t really be great for a future turbo. But would still be fine for motor mods or some spray.

I'm running a gen 1 tank already setup with external pump plate...

[knecum]

Any mods to mounting the dash?

.  My dash went in in about 10mins.  Just have to drill a few clear holes for the white posts up top and bend the tang for the fairing posts. And cut alittle of it out.  But super easy. And the bolts line right up. Mine looks like it belongs there

[sportbikeryder]

Just buy Steve's bike. Turnkey, ready to go!

[adrenalinejunkie]

Ive heard the gen2 output shaft is offset and so is the swingarm. Is there anything that needs to be done if using a gen1 arm and wheel?

Anyone know if a gen2 fairing stay will work on a gen1 nose without mods?

[wildphil69]

same offset on swingarm

[dave393]

Ive heard the gen2 output shaft is offset and so is the swingarm. Is there anything that needs to be done if using a gen1 arm and wheel?

Anyone know if a gen2 fairing stay will work on a gen1 nose without mods?

I am trying to figure out the offset, i bought a 04 motor with a gen 2  trans, i think my chain might rub on my gen 1  frame. it looks about .200 offset.
anybody know what to do?

[adrenalinejunkie]

I don't think there's an issue with frame clearance. The issue would be with the swingarm and wheel. I think it will work, but the chain may have a slight offset and wear sprockets quicker. Im stil searching facts about this, please share your results.

[dave393]

I don't think there's an issue with frame clearance. The issue would be with the swingarm and wheel. I think it will work, but the chain may have a slight offset and wear sprockets quicker. Im stil searching facts about this, please share your results.

The actual offset is .190, I ran a chain thru and checked clearance between frame and chain. I got .050 clearance. I don't feel thats really enough. I could make washers for the left side of motor mounting points (.190 thick) easy enough and then shorten right side parts. Then i just need a 08 cover and see how that fits up. The 08 shaft is about .400 longer.
Dave

[adrenalinejunkie]

I don't think there's an issue with frame clearance. The issue would be with the swingarm and wheel. I think it will work, but the chain may have a slight offset and wear sprockets quicker. Im stil searching facts about this, please share your results.

The actual offset is .190, I ran a chain thru and checked clearance between frame and chain. I got .050 clearance. I don't feel thats really enough. I could make washers for the left side of motor mounting points (.190 thick) easy enough and then shorten right side parts. Then i just need a 08 cover and see how that fits up. The 08 shaft is about .400 longer.
Dave

Good info. Keep us updated.

[fvance]

I have been running a gen 2 trans in my '07 for several years everything aligns perfectely, you just need to grind the inside of the sprocket cover so the nut/output shaft clears.

[mysticblu999]

Any mods to mounting the dash?

.  My dash went in in about 10mins.  Just have to drill a few clear holes for the white posts up top and bend the tang for the fairing posts. And cut alittle of it out.  But super easy. And the bolts line right up. Mine looks like it belongs there

I'd love to see a pic of that.

Sent from my SAMSUNG-SGH-I317 using Tapatalk 2

[adrenalinejunkie]

Running into a clearance issue with the chain touching the inside of the frame. Anyone have a good solution for this?

[adrenalinejunkie]

I don't think there's an issue with frame clearance. The issue would be with the swingarm and wheel. I think it will work, but the chain may have a slight offset and wear sprockets quicker. Im stil searching facts about this, please share your results.

The actual offset is .190, I ran a chain thru and checked clearance between frame and chain. I got .050 clearance. I don't feel thats really enough. I could make washers for the left side of motor mounting points (.190 thick) easy enough and then shorten right side parts. Then i just need a 08 cover and see how that fits up. The 08 shaft is about .400 longer.
Dave

Your setup is different than mine, but may help me with my clearance issues. Did you figure out what will work for you?

I have a Gen1 frame, extended arm and wheel BUT everything else is Gen2. Ive heard of offsetting the motor or machining down the counter sprocket.  Not crazy about either options, but may not have a choice. Please share your results.

[dave393]

I got the roller done and am ready to set motor in next. I got my cover and speedo pickup all fit on the motor real nice. Machined a spacer for the speedo pickup and made a hole in the sprocket cover and turned down the speedo rotor. I think the motor spacers is the best route to go.

[adrenalinejunkie]

I got the roller done and am ready to set motor in next. I got my cover and speedo pickup all fit on the motor real nice. Machined a spacer for the speedo pickup and made a hole in the sprocket cover and turned down the speedo rotor. I think the motor spacers is the best route to go.

What exactly did you do for the motor spacers?

[dave393]

I have not done it yet, but machine 3, .190 washers for the left side and shorten the right hand rear spacer .190, the spacers on the right are all adjustable. You could also shim the swingarm to the right with a couple extra washers on the left side of the pivot shaft. I think there about .030 thick. 2 might be enough to do the job and not worry about shimming the motor.