1998 - 1999 Fuel Injected Motor Conversion
Here's what you'll need:
* 2002 - 2003 Service Manual (available on this forum) - A MUST - You will need some electrical diagrams.
* 2002 - 2003 Engine & Throttle Bodies
* 2002 - 2003 Engine & Throttle Body Sensors (hopefully still attached to the engine)
* 2002 - 2003 Throttle Body Cables (the 98-99 cables are too short by 1/2 inch)
* 2002 - 2003 Instrument Cluster
* 2002 - 2003 CDI Box and Voltage Regulator
* 2002 - 2003 Air Box and Sensor
* 2002 - 2003 R1 or FZ1 EXUP Servo Motor (the 98 - 99 will work if you don't mind soldering some extra wires)
* 1/8" or 5/16" pipe tap/nipple for the return fuel line to the tank.
* 1/8" Pipe Caps (for Air Injection Block Off)
* 2002 - 2003 Complete Wiring Harness (including the front harness)
- If you can get your hands on another Yamaha donor harness, it will help out a lot. You will need some matching connectors. This is nice to have unless you don't mind butchering your 98 - 99 harness.
* 2002 - 2003 Relays & Pressure Sensors...
- Start System Relay
- Air Pressure Sensors (one on throttle bodies, one under seat)
- 2 Headlight relays
- Turn Signal Relay (same on all year models)
- Cooling Fan Relay
- Lean Angle Cut-Off Switch
- Start Solenoid (may be the same for all models)
* Master E 2000 In-Line Fuel Pump for a 76' Ford Bronco (Advance Auto Parts, NAPA, Auto Zone - $80.00)
- The 98 - 99 R1 Fuel Pump is rated at about 12 PSI of Fuel Pressure. The 2002 - 2003 R1 requires at least 48 PSI of Fuel Pressure. This Master E 2000 Pump is rated at 95 PSI. Works great thanks to the geniuses at Yamaha who put the fuel pressure regulator on the tail end of the fuel rail. Any pressure over 38-50 PSI (just a guess) is returned to the tank via the return line. It took me a while to figure out why the bike wouldn't run after I got it all back together. Then I found out that the stock 99 pump was rated at 12 PSI. The 2002 pump is rated at 48 PSI. Once I figured all this out, I searched for days to find a fuel pump that would work that wasn't HUGE. All of the fuel injected bikes these days have the fuel pumps mounted inside the tank. An early model Hayabusa pump would probably work ok, but they are pretty large. The Master E 2000 pump fits inside the stock rubber fuel pump housing.
If you are using your stock header on your 98 - 99 R1, hang on to it. The 2002 - 2003 stock header will not work on a 98 - 99 R1. The oil sump is deeper on the 2002 - 2003 motor. The 2002 - 2003 stock header is taller and will not clear the oil pan. The 98 - 99 stock header will work with just a little bit of grinding.
Take your bike apart. Pull out the stock harness, CDI, & Regulator. Remove the fuel pump, EXUP motor, Exup motor bracket, and carbs. Swap out the 98 - 99 throttle cables with the 2002 - 2003 cables. Remove the choke cable and choke lever.
Prep the 2002 motor for installation...
On the right side of the head, there is a motor mount plate that needs to be removed. Remove the 4 screws and take the plate
off of the motor. Use some permatex and seal the 4 screws back into the head. If you leave the screws out, you will leak vacuum from the holes ( I learned this the hard way). Also on the right side of the motor is a main engine mount bolt hole. Drill and tap that hole to fit the larger mount bolt from the 98 - 99 motor (I also learned this the hard way. The smaller bolt isn't quite long enough to mount as securely as I'd like.) There is plenty of metal there to drill and tap. No worries.
Make sure the EXUP motor bracket is removed before trying to mount the engine. Install the engine, thread the cables into the
throttle bodies and mount them to the motor.
The 98 - 99 radiator will work. You will not use the sensors on the 98 - 99 radiator. The 2002 - 2003 sensors are mounted to the thermostat housing. (hopefully included with the 2002 - 2003 motor).
The 2002 - 2003 gauge cluster will mount to the 98 - 99 bird cage / faring stay. You will need to open the hole up quite a bit where the harness connector goes through to hook to the gauges.
Sorry to say that I didn't take any pictures during the conversion. I will take some pictures and post them when I change the oil for the first time.
I'd be happy to answer any questions.
Mike
Here's what you'll need:
* 2002 - 2003 Service Manual (available on this forum) - A MUST - You will need some electrical diagrams.
* 2002 - 2003 Engine & Throttle Bodies
* 2002 - 2003 Engine & Throttle Body Sensors (hopefully still attached to the engine)
* 2002 - 2003 Throttle Body Cables (the 98-99 cables are too short by 1/2 inch)
* 2002 - 2003 Instrument Cluster
* 2002 - 2003 CDI Box and Voltage Regulator
* 2002 - 2003 Air Box and Sensor
* 2002 - 2003 R1 or FZ1 EXUP Servo Motor (the 98 - 99 will work if you don't mind soldering some extra wires)
* 1/8" or 5/16" pipe tap/nipple for the return fuel line to the tank.
* 1/8" Pipe Caps (for Air Injection Block Off)
* 2002 - 2003 Complete Wiring Harness (including the front harness)
- If you can get your hands on another Yamaha donor harness, it will help out a lot. You will need some matching connectors. This is nice to have unless you don't mind butchering your 98 - 99 harness.
* 2002 - 2003 Relays & Pressure Sensors...
- Start System Relay
- Air Pressure Sensors (one on throttle bodies, one under seat)
- 2 Headlight relays
- Turn Signal Relay (same on all year models)
- Cooling Fan Relay
- Lean Angle Cut-Off Switch
- Start Solenoid (may be the same for all models)
* Master E 2000 In-Line Fuel Pump for a 76' Ford Bronco (Advance Auto Parts, NAPA, Auto Zone - $80.00)
- The 98 - 99 R1 Fuel Pump is rated at about 12 PSI of Fuel Pressure. The 2002 - 2003 R1 requires at least 48 PSI of Fuel Pressure. This Master E 2000 Pump is rated at 95 PSI. Works great thanks to the geniuses at Yamaha who put the fuel pressure regulator on the tail end of the fuel rail. Any pressure over 38-50 PSI (just a guess) is returned to the tank via the return line. It took me a while to figure out why the bike wouldn't run after I got it all back together. Then I found out that the stock 99 pump was rated at 12 PSI. The 2002 pump is rated at 48 PSI. Once I figured all this out, I searched for days to find a fuel pump that would work that wasn't HUGE. All of the fuel injected bikes these days have the fuel pumps mounted inside the tank. An early model Hayabusa pump would probably work ok, but they are pretty large. The Master E 2000 pump fits inside the stock rubber fuel pump housing.
If you are using your stock header on your 98 - 99 R1, hang on to it. The 2002 - 2003 stock header will not work on a 98 - 99 R1. The oil sump is deeper on the 2002 - 2003 motor. The 2002 - 2003 stock header is taller and will not clear the oil pan. The 98 - 99 stock header will work with just a little bit of grinding.
Take your bike apart. Pull out the stock harness, CDI, & Regulator. Remove the fuel pump, EXUP motor, Exup motor bracket, and carbs. Swap out the 98 - 99 throttle cables with the 2002 - 2003 cables. Remove the choke cable and choke lever.
Prep the 2002 motor for installation...
On the right side of the head, there is a motor mount plate that needs to be removed. Remove the 4 screws and take the plate
off of the motor. Use some permatex and seal the 4 screws back into the head. If you leave the screws out, you will leak vacuum from the holes ( I learned this the hard way). Also on the right side of the motor is a main engine mount bolt hole. Drill and tap that hole to fit the larger mount bolt from the 98 - 99 motor (I also learned this the hard way. The smaller bolt isn't quite long enough to mount as securely as I'd like.) There is plenty of metal there to drill and tap. No worries.
Make sure the EXUP motor bracket is removed before trying to mount the engine. Install the engine, thread the cables into the
throttle bodies and mount them to the motor.
The 98 - 99 radiator will work. You will not use the sensors on the 98 - 99 radiator. The 2002 - 2003 sensors are mounted to the thermostat housing. (hopefully included with the 2002 - 2003 motor).
The 2002 - 2003 gauge cluster will mount to the 98 - 99 bird cage / faring stay. You will need to open the hole up quite a bit where the harness connector goes through to hook to the gauges.
Sorry to say that I didn't take any pictures during the conversion. I will take some pictures and post them when I change the oil for the first time.
I'd be happy to answer any questions.
Mike