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GEN2 ENGINE INTO GEN1 |
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redratbike
Moderator Group The Collector Messiah Joined: 07 May 2008 Status: Offline Points: 16147 |
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Posted: 06 Oct 2014 at 16:38 |
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not a how to guide as such but a source of info to all those thinking of doing this conversion
please note i have scoured the web and other aprilia forums so thanks to all whoever wherever they are for this valuble info
apologies if any of the info is copied over twice as its all in bits and bobs that has been saved in various places over the years
Easy swap. Use gen 1 front valve cover, tap holes for exhaust cam sensor and sensor and front exhaust cam sprocket from early motor. Use early flywheel and stator for correct crank trigger data, obviously the older To use the gen 2 engine in your gen 1 frame you will need to use the gen 1 ECU and wiring harness you will need to use a gen 1 flywheel , a gen 1 front valve cover & cam position sensor (you may need to drill and tap a mounting hole in the head for the sensor), You'll have to do a bit of grinding to get the gen 1 valve cover to fit, cut and weld gen 2 exhaust flanges on to your gen 1 exhaust or otherwise adapt a gen 2 exhaust to fit, get an EPROM designed for the Gen2 57mm TB and Siemens injectors (Gabro sells one), adapters for the injector wiring, convert the ignition from dual to single spark per cylinder, install a method for fast idle, and probably a couple of other small things I forgot. flywheel use a gen 1 unit So now I knew it was possible to use an 2004+ engine with early electrics by simply: Tuono Racing Heart Transplant (Part 1 - The Plan) |
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redratbike
Moderator Group The Collector Messiah Joined: 07 May 2008 Status: Offline Points: 16147 |
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in addition to the info above ..you can just do the gen2 head on gen1 engine trick
why would you want to do that i hear you cry.
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this is why
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I would not put a bigbore kit on stock unported twinspark heads... i consider it like a waste of money, as the heads do not flow enought for that pistons. It's almost a straight fit, it's only required a little rework on the front one and to modifiy the exhaust headers using IIGen exhaust flanges.
Using a proper eprom with the right ignition timing you'll have very good midrange and aboout 10hp more from 6-7000rpm to top |
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redratbike
Moderator Group The Collector Messiah Joined: 07 May 2008 Status: Offline Points: 16147 |
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good info when selecting the gen2 heads is the info below i have kept the gen 1 sizes for comparision ..
Valve sizes through the years....
.......... Inlet Exhaust 1998-99 36 31 2000 36 31 2001-02 38 31 2003 38 31 2004-05 38 31 2006 on 38 33 |
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davidrsurfer
Premium Member Joined: 22 Feb 2011 Location: North Devon Status: Offline Points: 2511 |
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Do you actually go to work? & if you do do you do anything when you are there?
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Motorcycle friendly self catering holiday apartment Acorn Studio. See us at Air bnb.
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redratbike
Moderator Group The Collector Messiah Joined: 07 May 2008 Status: Offline Points: 16147 |
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kiwi_rsvr
Premium Member EX Dr Frankie Stein (splitter) Joined: 10 Sep 2008 Location: Hockley, Essex Status: Offline Points: 3391 |
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I think Mark works for B.T , he is their "Internet Tester", he surf's so we dont need to.............
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jimgreg
Premium Member Joined: 10 May 2012 Location: Cornwall Status: Offline Points: 1584 |
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Awesome info Mark, Been thinking about a head swap for a little while now but can't bring myself to go to the no turning back to original point
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redratbike
Moderator Group The Collector Messiah Joined: 07 May 2008 Status: Offline Points: 16147 |
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NickyBoy1984
Moderator Group Exhaust freak! Joined: 24 Dec 2011 Location: Essex Status: Offline Points: 10532 |
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Oooo sounds exciting hehe, you could've done with that Evo6 system huh Hehee!
NickyBoy
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redratbike
Moderator Group The Collector Messiah Joined: 07 May 2008 Status: Offline Points: 16147 |
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The Tigcraft will finally come out to play I have it...so I haven't got to fork out more cash on the winter make-over...or should I say that cash may become a rear shock? |
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Diggs345
Premium Member Joined: 18 Dec 2013 Location: Lincs Status: Offline Points: 220 |
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nice thread , can you do one for degreeing cams , my heads spinning but iv got it now lol
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davidrsurfer
Premium Member Joined: 22 Feb 2011 Location: North Devon Status: Offline Points: 2511 |
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Motorcycle friendly self catering holiday apartment Acorn Studio. See us at Air bnb.
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redratbike
Moderator Group The Collector Messiah Joined: 07 May 2008 Status: Offline Points: 16147 |
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My work is in fits and starts ...I'd blitzed everything by 11am..... Then I had a late afternoon rush...but everyday is different |
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Nooj
Premium Member Official nut shiner, and nutter! Joined: 28 Jul 2010 Location: Newbury Status: Offline Points: 393 |
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Nice find! Thanks for posting it. Will come in useful here ;-)
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Shiny Bike Syndrome Specialists in motorcycle valeting and VentureShield fitting.
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Jollygiant
Premium Member Carbon Whore Joined: 06 Aug 2012 Location: Naughty Step Status: Offline Points: 1265 |
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Why not just use the Gen 2 loom and mod it where necessary, surely that would be much easier than having modded ecu's, alternators and stuff made.
As all you may need to do is lengthen or shorten small areas of wiring.
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cheesy
Premium Member top chef! Joined: 11 Feb 2008 Location: Peterborough Status: Offline Points: 1746 |
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I've just done/finishing this conversion at the moment.
It's been pretty straight forward plus I'm doing my own twists to the conversion. I'm just waiting on a part from the states to arrive then I can fill with oil and coolant Wiring is all in place just a touch of soldering to do as I wanna make it clean factory look |
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04 Tuono Fighter
1060 gen2 motor & some.... |
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IanG
Premium Member Joined: 04 Oct 2010 Location: N Wales Status: Offline Points: 10725 |
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Gen 2 is CanBus controlled |
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Jollygiant
Premium Member Carbon Whore Joined: 06 Aug 2012 Location: Naughty Step Status: Offline Points: 1265 |
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And what difference does that make? Use the whole loom and theres no problem, is there??
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Check out my pre-preg carbon fibre
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IanG
Premium Member Joined: 04 Oct 2010 Location: N Wales Status: Offline Points: 10725 |
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Good luck then
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WARNZ
Premium Member Joined: 10 May 2012 Location: Essex Status: Offline Points: 1171 |
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If using the Gen2 loom ecu and clocks too as Ian said can-bus system don't think it would be a issue,butt the Gen1 ecu(chip) is easier to modify map so that's why this route is taken I think
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cheesy
Premium Member top chef! Joined: 11 Feb 2008 Location: Peterborough Status: Offline Points: 1746 |
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Gabro writes a specific chip for this conversion.
It's the only one he does that requires a doughterboard. |
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04 Tuono Fighter
1060 gen2 motor & some.... |
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jimgreg
Premium Member Joined: 10 May 2012 Location: Cornwall Status: Offline Points: 1584 |
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So guys a question about Gen2 cyclinder heads on a Gen1 engine. Does it take a lots of messing about or is it simpler than thought.
Thanks
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cheesy
Premium Member top chef! Joined: 11 Feb 2008 Location: Peterborough Status: Offline Points: 1746 |
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Fairly simple once you understand what's involved.
Get the late gen2 heads, have 360 stamped in the exhaust port. I'm just in process of doing another gen2 motor on gen1 electrics but in a gen2 frame |
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04 Tuono Fighter
1060 gen2 motor & some.... |
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jimgreg
Premium Member Joined: 10 May 2012 Location: Cornwall Status: Offline Points: 1584 |
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Ok cool, thanks for that.
What's the difference in early and late Gen2 engines then? Are different ones easier to fit? |
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cheesy
Premium Member top chef! Joined: 11 Feb 2008 Location: Peterborough Status: Offline Points: 1746 |
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Exhaust valve size is bigger on 06 on.
Marks posted all the valve sizes further up this thread
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04 Tuono Fighter
1060 gen2 motor & some.... |
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