Engine Swaps Info

[trike_flyer]

Hello all

I hear a lot of talk of replace the engine with this one or that one, but I never hear anything on how hard it was to do. Can someone that has done an engine swap on a machine give us the lowdown on the problems encountered. Things like bolting the engine down, is it a direct bolt in? How about belt length, was it the same or differant and how did you measure it. I have seen some stuff on belt width issues, just need to change the clutch shimming or new clutch if to big a change.

I ask this as my OH160 seems to have blown the oil ring on it and the altinator is gone. I could repair it but it is cheeper to replace with a new engine than repair it. I even get a bit of an increase in power with the new engine. Maybe we need a howto just for it as it is very common to be done.

[racerone3]

there are so many variables, that it would be hard to do a how to that would apply to all models and engine types. every swap i've done has required building a new motor mount (yours may not as a lot of 4 strokes use a standard mounting platform). i try to build a mount in a manner that i can use a belt i already have. if i'm building the mount anyway, i can save time/ money/ energy not having to search for a belt once the work is done.
you will also have electrical to deal with. some harnesses can be adapted to the new engine, but i find it easier and better just to build a new one. most newer 4 strokes require 5 wires to run, stop, and charge. for around $50 at NAPA you can buy 5 rolls of wire, a new ignition switch, wire loom, and some terminals to do the job. i like the piece of mind of knowing that my wiring is not going to give me issues.
you also may require a new clutch for the engine. in your case your old one may work fine. if you were going from a 2 stroke, the old one wouldn't work at all.
there is also the exhaust to deal with.