here is some information regarding the engine conversion i did last month.
Just for the small chance someone might need it. I wish someone knew this while i was working on it.
ok well here we go...haha
You know the story of how i had all the 1997 sensors hooked and they all just bolted in.
Tried to run it but no spark!
I figured out with the help of a guy down road. He told me i'd need to change gear behind the lower timing gear.
He is also the guy i got the 2004 (7153 km's) engine from.
We figured out that timing chain gear on the crank was wrong. This is where it got tough. The lower timing gear has another gear(sproket shaped) attached to the inner side of it. The inner sproket is what the signal generator picks up the pulses off. The pulses tell the computer when to fire the plugs.
2004 inner sproket 15-20 teeth ( cant remember exactly, but it just looked like a gear)
1997 inner sproket 3 teeth and one raised portion.
LOL thats why I'd get a "spark ever so often". The computer was confused.
So......... you get into the lower timing chain cover.
Move to TDC........
Zip tie cam gears to chain to keep there possition.
Mark chain and lower sproket so you know where it goes back. Remove tensioner.
Remove tensioner arm bolts.
Then remove the lower timing chain sproket.
- I had to plug the oil holes and cut the gear cause it would not clear the tensioner arms.
- The 1997 gear does clear because it only has 4 teeth.
Problem here too. Now you must cut one of the inner splines in the timming chain sproket cause the 2004 crank has a alignment flat spot on it.
Before you do that you gotta figure out what tooth you need to cut out. I found a web site for EVERY SERVICE MANUAL. Downloaded the PDF and printed it out for the 1997 gsxr 497 pages lol. It has a great diagram on where all the gears line up. In regards to TDC.
After the tooth is taken out slide the timing gear on and re assemble your bike.
fired right up!!! I have drove 3000 km's now and it is awesome!!!!