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HOW TO: 98 R1 To 03 R1 Motor Conversion

32K views 24 replies 9 participants last post by  djcloud  
#1 ·
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
 
#2 ·
wow... very interesting...
hows it run????
You glad you did it???
is it worth it????
thanks
 
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#3 ·
Yes, I am very glad that I did it. It was a pain in the ass, but well worth it. No more messing with jet kits... :>) Now just make some changes in the power commander and RIDE. When I started, I had no idea how much damage was done to the 02 motor. It came out of a wrecked bike with about 1,200 miles on it. With all of the switches and safety devices on the 02 motors, I figured if the bike was laid down, the lean angle cut-off would kill the injection and save the motor. I was wrong. No idea how it was done, but the clutch was grenaded, destroyed, powdered, etc... It was in bad shape. I figure the only way it could end up like this was if the rider was in the rev limiter and dumped the clutch. There were clutch fibers in the oil pan, oil filter, stator, starter cover, everywhere. The worst clutch fiber fragment was wedged between the crankshaft and the clutch basket. Needless to say, 6 teeth on the crank were bent. After replacing the crankshaft, cleaning all the crap out of the motor and replacing all bearings, the engine was reassembled and installed.

After all that, It is still worth it. the only thing that I don't like is the changes that were made in the gear ratios between 99 and 02. 2nd and 3rd gear are almost exactly the same. Probably not a bad thing... just not used to it yet. One other thing that I noticed between the 99 and 02 motor is a noisy transmission in the 02. I've asked around and it seems that a lot of the 02 03 R1s have the same noises???

Mike
 
#4 ·
I'm contimplating this conversion. I've got a 99 r1 as well... I've been looking around for a engine to pickup, i've seen several on ebay for as low as 500ish.. If you could give a little more feedback as to how the bike responds having FI i'd appreciate it.. I'm very interested to know the differences, and what you like and don't like about the conversion. Does the bike handle differently?
 
#5 ·
I give you credit for completing the mod, but why....

you should've just gone out and bought a 2002. You've already bought half the bike, you've spent countless hours tweaking, you had to modify the mount points on the frame and/or engine.

the engine isn't even any stronger than the pre-02 engines, so you've done all that just for FI. the best part of the 02s was the revised chassis, not even the FI.
 
#8 ·
Mike,
give us an update.... hows it running???
I have my 2001 frame... I know the brackets are a litte different between the 99 and 00 frames...
I am looking to pick up a motor at the end of summer...
any pictures yet???
does the 99 body work fit on fine??? any issues???
 
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#9 ·
Here are some pictures of the conversion. I finally got around to posting them. I have had no problems since I finished the conversion... It still runs great. I am putting the bike up for sale if anyone is interested. No time for it, and the money could be put to better use.

Mike
 

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#17 ·
sweet.....
I am doing that to the bike I am building.. just need a motor for my 2001 frame....
 
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#19 ·
BlaziN R1... I did pretty good because I found a wrecked bike that had everything I needed with the exception of a few things (relays, fuel pump, etc.) Other than the parts needed, it just took a lot of time. I'd imagine that it could get pretty expensive if you had to get the parts from a bunch of different places. I paid about $1,500 for the entire motor, harness, air box, cdi, and the regulator.

Mike
 
#21 ·
Just thought I would add my $.02

Ive done about 10 of these...The bike Im currently building for myself is going to be a 99 with 03 everything.....again...hahaha

If you just do the motor, you can pick up a 02-03 motor for about $1300-1500 and you can sell your original motor for around $1000-1400. So all in all, you can either make some money doing the conversion or lose about $200 or so....

When I rebuilt my old R1...it was a 00 with 03 Everything....I actually made almost a grand doin it! Enough to get a new exhaust, scotts, full tank of gas and part of my tuition for that quarter in college!!

I had perfect 00 fairings and low mile motor, I sold the fairings for $1400 and sold the motor for $1500, and I bought an 02-03 motor for $1000 shipped and 02 full fairing set for $1100
shipped and they were all in perfect condtion!

Here is a couple pic!!!

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#22 · (Edited)
hey DJ do the mounts line up in the 00 frame to receive a 02
motor?
thanks highside:jump

oh and your pics didn't work.
I have complete 02 motor with gauges and wireharness complete w/ecm's etc.....guess I just need a fuel pump? right?
Is the fuel pump removeable from th 02-03 tanks and can it be fitted into an 00 tank?

thanx again
 
#23 ·
yo! My server was down, and on some computers(work, school) you cant veiw my pics cause they are on a private server and some computers are configured to block those...

anyway, ya everything mounts up, though you have to remove the 02-03 right side upper mount bracket, cause it wont fit in the frame if its still there. and you have to make sure you teflon the screws and put them back in otherwise you will have a vacuum leak.

The fuel pump is not able to put in a 98-01 tank, there isnt a hole big enough in the tank...it would be easier to just swap the tank to 02-03 or get an inline fuel pump that pumps roughly the same amount as the 02-03 Fuel pump.

hope this helps!
 
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