Next up: Project bike. 2007. Picked this up for a good price, but had a hole in the motor, right above where the clutch is. Tim (Backmarker on here) was over at the house and guessed the clutch exploded. As soon as I popped the clutch cover off, I knew he won the prize. The basket literally exploded. I have no idea how. All I know is that there were pieces everywhere, no part of the basket to be found in one piece, and the crank had managed to suck up pieces of the discs/basket/ into #4 and somewhere along the way, shit got in between the piston and valves, and the intake valves got bent to shit. All I know is that this thing had to make one HELL of a racket when it exploded.
I just happened to have an extra '09 motor laying in my garage (I told you I have a lot of shit), and from my googling on here, it seemed I could just swap motors, because it's the same motor. Swap motor out, sell it, easy day.
It IS the same motor, but it's not. Yes, it will physically bolt into the frame, but there are several key, very important differences:
The 07-08 wiring harness uses a camshaft position sensor. The 09-12 does not. The 09 head has the casting built in where that sensor would bolt to, but it's not physically drilled or tapped for it. Well, so much for just a motor swap...
Stator plug is different, tip over sensor plug is different. Throttle bodies, while using the same electrical connectors, are different as well. The 09-12 TB's are about a 1/4" taller. This made my choice for me...swap over the harness to the 09-12. Not that big of a deal...since I had an extra harness
The upper engine mounting cast on the 09 is skinnier than the 07. I just so happened to have this random aluminum spacer (I never throw away usable nuts/bolts/spacers) that worked perfectly. You can see the brushed aluminum spacer being put to work. Where did it come from...no idea. All I know is that it worked perfectly and it was literally the exact size I needed. I suppose you could always make a sleeve or stack a shit ton of washers if you wanted to.
The '07-08 air box DOES fit on the 09-12 throttle bodies, which is good...because the 09 air box won't fit as the frame is too skinny on the 07. That is where I'm currently at - pulling out the '07 harness and putting in the 09. This gives me a spare harness for my personal '07...not a bad thing. Long term, I plan to completely strip that harness and make it race only and swap it over to mine. that will clean up the wiring on it and not make my eye twitch every time I take off my race bodywork.
Thankfully the transmission in the blown up engine appears to be good. Another track side spare.