Engine swap advice

Message

HisNibbs · #1 Post by **HisNibbs** » Mon Feb 15, 2016 10:19 am

Hi, I'm looking at swapping my 120K Kilometer Falco motor for a 40K K. 2002 RSV motor. (Thanks Pete for the heads up)

Any pointers, hits, tricks or things to watch out for?

Is it likely to be a big valve head? How do you tell without taking the heads off?

I believe that I'll have to reverese the gearshift linkage (go below rather than over the top? or put on a lever direst to the gearbox shaft?)

Falco headers fit?

Oil cooler?

Throttle bodies ok?

Falcopops · #2 Post by **Falcopops** » Mon Feb 15, 2016 1:31 pm

AFAIK the headers and the throttle bodies will be a direct fit.

One thing I know for certain is that the coolant line setup is different, I was looking to get a set of samco silicon hoses and they were subtly different around the thermostat/water pump area. Dunno if that'll cause any significant issues.

I'm pretty sure this has been done a number of times and a mechanical genius like yourself should have few problems

MartDude · #3 Post by **MartDude** » Mon Feb 15, 2016 6:26 pm

Call Griff, & pick his brains

fatboy · #4 Post by **fatboy** » Mon Feb 15, 2016 7:07 pm

The oil cooler set up is different, think it will be far easier to use the falco set up.
Falco lines are both in/out on the top of the rad.
Depends on what you get in terms of aux parts.
Hope this one works out for you and good luck !

blinkey501 · #5 Post by **blinkey501** » Mon Feb 15, 2016 7:45 pm

Straight swap. Use all your falco bits

I will compare the gear levers on the mille/ falco?

I am sure the falco one will fit straight on and give you 1 down 5 up.

I have been wrong before though.

blinkey501 · #6 Post by **blinkey501** » Mon Feb 15, 2016 8:01 pm

And the big valve engine can be identified by the engine code on the rear of the engine between the exhaust port and sprocket cover?

It is directly on that line?

HisNibbs · #7 Post by **HisNibbs** » Mon Feb 15, 2016 8:06 pm

Hi Jay, what would the code include on a big valve motor?

blinkey501 · #8 Post by **blinkey501** » Mon Feb 15, 2016 8:08 pm

HisNibbs wrote:Hi Jay, what would the code include on a big valve motor?

I would have to look in my garage at the motor I have on the floor?

Griff knows the codes off by heart?

blinkey501 · #9 Post by **blinkey501** » Mon Feb 15, 2016 8:10 pm

If you do have the big valve motor, you may need a chip for the mille?

The tuning charecteristics are similar until you hit 6000RPM? Then the mille engine comes more alive.

Aladinsaneuk · #10 Post by **Aladinsaneuk** » Wed Feb 17, 2016 12:02 am

As you have an early falco, I think that the radiator and oil cooler plumbing will be a straight fit from falco to Mille engine

The falco oil tank would therefore have to be used

If you end up with the Mille oil tank the headers will still fit

GregD-UK · #11 Post by **GregD-UK** » Fri Feb 19, 2016 8:42 pm

Hi all.

you need the ecu and clocks to marry up with the engine! Otherwise the tucker won't start. Pierre found out this to his cost.He also managed to squeeze the anglular swingarm in with a bit ofcutting on the battery box. He fitted one of those slimline batteries anyway...

Enjoy the swop, would fit the falco cooling system and oil tank. Unless you change the exhaust setup...

HisNibbs · #12 Post by **HisNibbs** » Fri Feb 19, 2016 10:03 pm

I now have the motor and according to the engine number it should have the larger valves. it didn't come with oil tank or rads and is also missing a couple of sensors. It did come with throttle bodies though.

It didn't come with ECU (is that the same as the chip?) I have a standard Falco and a Gabro mapped to Falco's evo air box and RC can configuration. I would have thought it would at least run with the Gabro chip and other bits and pieces brought across. GregD-UK or anyone else for that matter, do you know what is different about the ECU?

I’spose I can talk to Griff next week and see what he says, I did talk with Lewis last week when I rang and Griff was out, he implied it should be a strait swap.

One niggle sofar is that it has what looks like a small Jd weld patch on the rear crankcase just beneath where the rear header would exit. Sign of some one getting frustrated in an earlier life...

Aladinsaneuk · #13 Post by **Aladinsaneuk** » Fri Feb 19, 2016 10:11 pm

Iirc the Mille and falco clocks are inter changeable

If it comes with the Gabri chip, then I assume that will work though you may well need to consider changing the exhaust - your falco pipes and headers will still fit, as indeed should the oil tank

I guess you need to get the engine in the frame and see :)

HisNibbs · #14 Post by **HisNibbs** » Fri Feb 19, 2016 10:26 pm

It didn't come with a chip Pete, the Gabro referred to is the one currently in the Falco.

HisNibbs · #15 Post by **HisNibbs** » Mon Apr 25, 2016 6:46 pm

We-hey fired up first push of the button.

Got some tidying up still to do but I was very pleased to hear the beasty rumbling again. Sounded pretty good to me.