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51K views 129 replies 50 participants last post by  BSR-1  
#1 · (Edited)
Well I'm kicking off this Fall/Winter STRONG and starting my engine swap early, I'll be using this thread to update my progress as I go along.

What am I doing?

--I'm installing an 07 R1 engine/intake/harness/ecu/cluster in to my 04 R1

Why?

--Lower mileage engine and 16 valve head

_________________________________________________________________

10-18-2009
--Picked up the 07 engine/intake/harness/ecu/cluster
--Started the tear down of my 04.

Pictures:

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_________________________________________________________________

10-19-2009
--Disconnected all items from the harness, removed kickstand, drained oil and coolant, supported the engine with a hydraulic jack, removed engine mount bolts and bolt sleeves, lowered the engine out and wheeled it out of the way
--Removed AIS system from 07 engine and replaced the spark plugs with NGK Iridium plugs

*Findings; discovered that I must use an 07-08 fuel pump assembly due to the non-return line fuel rail on the 07 engine. Looks as though I will need to swap some of the coolant lines from the 04 engine over since I am still using an 04 radiator.

Pictures:

07 Engine w/ new plugs and AIS removed
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04 engine w/ full harness
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Super light-weight R1
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Exhaust, 07 harness/ecu/intake box (and other junk from my garage)
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My, now occupied, garage
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10-19-09 Part 2
--Bolted up the engine and began tracing the harness paths.

Pictures:

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_________________________________________________________________

10-20-2009
--Routed crankcase vent to the valve cover (instead of going with BOP's).
--Installed the cooling system
--Test fit the intake box
--Purchased a BMC Race filter and PCIII

Pictures:

What you see here is where I routed both AIS plates into a vacuum 'T' and the hose coming in from the crankcase
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_________________________________________________________________

10-22-2009
--Harness is installed and 80% connected
--Wired up the front end and installed the nose fairing/windscreen
--Contemplating how to organize/mount everything in the subframe (the 07-08 use a different configuration than 04-06)
--Having trouble locating the harness connector for the rear brake switch

*Findings; I needed to purchase the 07/08 rectifier and mount (this goes in the ram air opening before the airbox), atmosphere sensor and mount (this goes where the 04-06 ecu use to go), and intake sensor (located in one of the ram air tubes on the 07-08). Since the ecu is in the subframe on the 07-08 I either need to purchase an 07-08 subframe or custom mount everything (I will be custom mounting everything until I come across a killer deal on a SF).

Pictures:

Nose fairing installed, the front is ready to go
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07-08 cluster
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Showing a portion of the harness
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Does anybody know what these two connectors are for? I am guessing one is for the o2 sensor and one is for the rear brake switch, if so, which is which?
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_________________________________________________________________

10-23-2009
--Custom mounted everything that belongs in the subframe.
--Connected the new PCIII

Pictures:

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#2 · (Edited)
_________________________________________________________________

IT'S ALIVE!

10-24-2009
--Installed the rectifier (custom mounted to the old plate, not the one from the 07-08)
--Installed the atmosphere sensor and it's plate that blocks off the ram air section from the engine bay
--Installed the air sensor in the left ram air tube
--Installed the 07-08 fuel pump and then mounted the tank (the new airbox is taller and thus it hits the airbox cover that mounts to the tank, no solution yet but I think the 07-08 airbox cover might work on the 04-06 tank so I'm going to find a local one to test fit before I decide to buy an 07-08 tank)
--Installed the exhaust and noticed that the exhaust ports come out at a different angle on the 07-08 engines so before I source I 07-08 header I just 'tweaked' mine a little
--Installed all the fairings (the left side lower fairing had to be trimmed since it was hitting the coolant hose, no pictures of this as it's not noticeable when the fairings on installed)
--Still waiting on the front sprocket nut and no rain before I can ride it.
--With the shorter exhaust and BMC filter I can almost definitely tell that it will need a tune.

Video :D :

http://www.youtube.com/watch?v=JEkqiRoy7CE

Pictures:

Rectifier mounted to the original lower plastic piece
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Atmosphere sensor on the left
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Airbox mounted and BMC race filter installed
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Airbox lid installed (the lid is much higher than the 04-06 lid)
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Oh no, where's the oil fill cap?? (hidden under the lower fairing wing)
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The gap from the airbox cover hitting the top of the airbox which won't allow the tank to sit flush
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J
#3 ·
sry i can not answer your question, but i do wish you luck
 
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#7 ·
Nothing, it just has 23k on it and swapping the engine is cheaper then a rebuild IMO. I'm sure the engine would last much longer but it's winter time so why wait.

It will actually be up for sale soon, I took a video of it running for the last time before I started the tear down.
Engine/intake box/harness/ecu will be forsale along with the billet Roth stacks and PCIII.

StormRydeRz said:
That sounds like a HUGE headache. Wouldn't it be easier to just sell your 04 and buy a used 07-08? That's gona be alot of modifications with the two bikes being so different with electronics and such, but good luck!
Click to expand...
The glass is half full.
There is no way I could end up with an 07-08 R1 with as much done to it as I have done to my 04 without spending a lot more money.

KEEP IT DOWN said:
I agree!

You would need to change the following:

ECU
Wiring Harness(Not sure if 07 Harness plugs into everything from 04?? ex. Cluster, Ignition...........)
Fuel Pump
Fuel Rail
Exhaust(Header at the least)


Not sure if the Air Box for the 07's will fit under the 04 Tank. Ram Air tubes are smaller on the 04's so not sure how you will hook that up to work.

There is a lot of headaches. Would of been much easier to rebuild or buy used 04 motor or jsut sell your 04 and buy and 07.

Either way good luck to you!
Click to expand...
I am swapping in the following parts:

07 engine, harness, ecu, airbox, and cluster; looks like I will be picking up an 07/08 fuel pump as well.

The headers should bolt right up to the head, the major difference in the 04-06 and 07-08 exhaust system is where it passes the swingarm and my current exhaust doesn't use either route.

The ram air tubes have nothing to do with the intake box, the connect directly to the frame and the airbox is fed through the frame.

There is no doubt that this will be a slight challenge but not nearly as much as you all are making it out to be.

I had two ways to do this, swap in the motor alone and run it with my 04 electronics/throttle bodies/intake box and modify the timing advance unit in the engine, followed by a major tune.

OR

Bring everything from the 07 over essentially making it an 07 R1 in an 04 frame.
 
#6 ·
I agree!

You would need to change the following:

ECU
Wiring Harness(Not sure if 07 Harness plugs into everything from 04?? ex. Cluster, Ignition...........)
Fuel Pump
Fuel Rail
Exhaust(Header at the least)


Not sure if the Air Box for the 07's will fit under the 04 Tank. Ram Air tubes are smaller on the 04's so not sure how you will hook that up to work.

There is a lot of headaches. Would of been much easier to rebuild or buy used 04 motor or jsut sell your 04 and buy and 07.

Either way good luck to you!
 
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#14 ·
While it may easier to do some of the things suggested by others on this thread, the easiest path is not always the most rewarding. Sometimes it is just more fun to mod what you have and do it with your own hands so that when you step back you can say I did that and it is mine. Rock on man!!! I have an 04 and it would have been a lot cheaper to buy a newer bike than to pour the money into it that I have over the past year, but it is sentimental to me and I like that one. We have 33K miles together and a few times down on the pavement but we are still here together and rocking!
 
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#15 ·
I am eager to see this done as well but there is way too much that will be needed to change.

Does the Headlight, Tail Lights all plug intot he harness as well from 04 into 07?

This definitely a lot of work and it can work its just figuring out everything you will need to change before hand rather than when you come across it and realize then. It will just set you back some time thats all and be frustrating.

Good luck and keep us posted!
 
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#16 ·
I appreciate all the encouragement and eagerness to see the progression of this project, if there's one thing that make this easier it's having the support of others.

I will update the thread in a few minutes once I upload the latest photos.

KEEP IT DOWN, the harness looks shockingly similar to my 04 in terms of plugs, I do not believe I have come across any connection that will need modifying (from the headlights to the taillight). The one major issue I have come across at the moment is the fuel systems, the 07-08 does not use a return style fuel line so I am required to swap out my fuel pump assembly for one from an 07-08 (one is shipping out to me tomorrow).
 
#17 ·
*post updated

I am debating what to do with the AIS system removed.
I've ordered block-off plates but I have read about others who have routed the crack case breather to the valve cover (via the AIS plates).
Any suggestions?
 
#23 ·
sub...
 
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#27 ·
I removed the AIS system but left the AIS plates on the head and routed them to the crankcase vent. Doing this will create negative pressure in the crankcase, more so than what using a Krankvent will create.

r1forever80 said:
Good luck with this. Ill be following it. If any of the plugs on the harness look different but have the same wires get a teminal tool so you can take the terminals out of the 07 harness and put in the harness plugs of the 04. Good thing is you have both harnesses and you can keep what you need from either. If you do it that way you wont have to be splicing wires.
Click to expand...
Thanks for the tip, I hope I don't run in to this but at least I'll know what tool I need. The only parts left on the bike with connectors are the forward controls (which I believe are interchangeable), the radiator fans (two wire connectors) and the rear brake switch. I'll post up if I missed something and it comes up that I'll need to remove the terminals and swap plugs. :thumbup
 
#26 ·
Good luck with this. Ill be following it. If any of the plugs on the harness look different but have the same wires get a teminal tool so you can take the terminals out of the 07 harness and put in the harness plugs of the 04. Good thing is you have both harnesses and you can keep what you need from either. If you do it that way you wont have to be splicing wires.
 
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