engine case swap

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wayne billings

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Hello I have an unusual question. Is a swap of 94' engine case with '86 internals possible. I am hoping it is a direct swap. I do understand that the crank, balancer and final drive has to be delt with. are there any problems with the clutch, water pump ,transmission or heads. thanks for any insight or previous experience.
 
AFAIK yes a swap is possible but the pick-up coils are different. 2 on the '86 & 1 on the '94. The generator rotor is different to account for that. Wire harness is different also. The gauges cluster may have a difference also. Do a site search for that information.
 
Yes, will need to re-size your plane bearings for the crank, rods, and balancer. Probably check clearances of transmission shafts and middle gear too.

Mark
 
As Far As I Know. That's fine. Cases are mated to the internals so if changing the cases, will need to re-do the plane bearings, etc. I don't think you need to worry about the final drive.

Mark
 
Most parts will swap over without issue. You will need to refit bearings to match the bore specs of the new cases. There isn't much cheaper out there and no aftermarket options for bearings.
 
Early '85-'89 engines use a 5 lead wire from the two pick-up coils, while the '90-'07 use 2 wires from the single pick-up coil. A search on here using my screen name and pick-up coil will get you pictures .

Here's the 5-wire one.

1731458648883.png
 
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OK< tell us what is the year on your steering head decal. What market (Country) does it say the bike was made-for?

This list says, France. 1986, & 1988. DPS color=Deep Scarlet; ARE=Apple Red

1731499479598.png


1731499724356.png


Finally, a picture of the 2-lead 1990+ pick-up coil system electrical lead.

1731500200106.png

https://www.vmaxforum.net/threads/vmx12-factory-service-manual.52788/

Here's a list of yearly changes that could tell you what you have, or what has been switched over the years. Unfortunately the factory shop manual link isn't working today.
 
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