New engine in old frame?

**Rikard the Swede** · #1 25 Aug 2003

Hi everyone,

Is it possible to install a new (model 2002 for example) engine into an old 1VJ-frame?

Does it take a lot of modifications or can you just bolt it on?

(I will probably be excluded from this forum for being a heretic now...)

With best regards

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Rikard the Swede

**KlausXT600** · #2 26 Aug 2003

best you can do (to change the engine i mean ). definitly the best xt600 engine ever build.
it will fit 1:1, mechanically.
if you keep the 1VJ alternator, there is no problem.
you will need a new clutch cable.
if you want to overtake new alternator, you need also ignition unit and -coil.
more or less tricky mods on the wiring are necessary (better: use 3tb wiring, switches, relais etc.).

regards
klaus

**Rikard the Swede** · #3 30 Aug 2003

Hello,

That sounds great!

Thanx for your help Klaus it´s great to get good and reliable expert advice on these things.

With best regards,

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Rikard the Swede

**Rikard the Swede** · #4 31 Aug 2003

Hello,

That sounds great!

Thanx for your help Klaus it´s great to get good and reliable expert advice on these things.

With best regards,

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Rikard the Swede

**Rikard the Swede** · #5 27 Dec 2003

Ah!

I have found an engine, a -94 with 20000kms on the clock.

What do you suggest, could I keep the alternator from my 1VJ, or is it better to change the CDI/Coil to the new one.

I will swap my old engine for the new one, and I need to know what to keep and what to replace with -94 stuff (carbs, CDI, Starter, Electrics and so on).

Thanx

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Rikard the Swede

**Rikard the Swede** · #6 7 May 2004

Hello again!

Now there is a -94 XT600E engine in my 1VJ frame!

The wiring was a nightmare and took me about 20hrs to sort out.

I used the old wiring from the 1VJ because I didn´t want to change all the other components on the bike, so now it´s -86 in all but the engine CDI and coil.

If you´re not very good at electrics, don´t try to keep the -86 wiring.

Otherwise the engine fit 1:1 perfectly!

You´ll need to change some oil lines and refit the rev. wire to the new engine but everything fits from -86 to -94 without mods.

I can recommend this swap, and i think that the mileage on a -94 is better than a -86.

Am I right Klaus?

**KlausXT600** · #7 10 May 2004

yep, exactly!
we can exchange experiences on the swedish tenere meeting, i will be there!

regards
klaus

**Rikard the Swede** · #8 14 May 2004

Hi,

Sorry I´m currently on a training schedule for work, so I can´t make it to the meet.

AND, the engine is making trouble again, this time I don´t know what to do...
The engine runs very poorly on full throttle and when decelerating after giving it throttle. This is while riding. Trying to keep a constant speed on any revs is impossible, it runs very bad.
No misfires though, just seems like poor mixture.
When I pull out the choke, the problem goes away.
New cylinder to carb. hoses, and a new spark plug.
Is there a screw to adjust the mixture, and where (on a 3TB) and how is the shop default setting on it?

Please, it´s my girlfriend´s bike and she is threatening to go off and buy a new F650GS instead.

Regards, R

**bigbrummer** · #9 14 May 2004

It might sound obvious, but have you checked and thoroughly cleaned the air filter?
I've just had a similar problem with my 55W after a rebuild, and after trying everything else, thats what it was. If not enough air is getting through, pulling the choke out would help. Its worth a try before you mess around with the carb.

Cheers Dave

**Rikard the Swede** · #10 17 May 2004

Hi,

Well, all hints and tips are useful, you never know wether you forget some of the basics...

No, the filter is fine, the bike runs very lean. I just took a 1150km small testrun and the bike ran om 0.42litres/10km.

That´s not very rich, is it.

What are the shop settings for the carb on a 3TB, anyone?

Help!

Regards!

**KlausXT600** · #11 17 May 2004

you will find it here:
http://www.xt600.de/xt_werkstatt/%2B...aten_xt600.htm
but since engines are the same and you still use 1VJ airbox and silencer, you should stay with the 1VJ-carb settings. these are:
main jet: prim. 145 / sec. 125
prim. needle: 5C41 / middle position
sec. needle: 5X72/ middle position
idle jet: 46
idle mix. adj. screw: ~ 2,5 turns
sync.: sec. carb opens when prim. carb. is 7 mm open

i assume that airbox is modified, otherwise 145 might be too lean under certain conditions.

check choke function, the choke cable is a trouble maker. better substitute by 2KF or 3TB choke (needs small mod. in 1VJ carb)

dismount fuel pump, that is also a trouble maker.

good luck,
klaus

**Barry Johnson** · #12 20 May 2004

How are the inlet rubbers? If they are knackered or leaking that could be the cause.

If they are loose or leaking, when you open the throttle the vacuum sucks the cabs onto the head, making a better seal and making the enging run better. However when you are on part throttle or no throttle, the leak will come back and make the engine run badly.

Theory sounds good - how are your rubbers?

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Barry
3AJ Tenere

**FredXTZ** · #13 21 May 2004

You have more vacuum between head and carbs with less open throttle.

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Fred, XTZ660, Holland.

**Rikard the Swede** · #14 29 May 2004

Hi,

Well bought new inlet-rubbers and a new spark plug, so I´ve eliminated that cause, I´m disassembling/checking/cleaning the carbs today.

I´ll let you know...

Regards / R.

**Rikard the Swede** · #15 29 May 2004

Oh by the way, I´ve bypassed the pump - didn´t work and the choke is the 3TB-type that is just a pull/pushbutton on the carb.

And the airbox is modified.

Regards...

( Thanks for all the good hints you guys! )