Fmyers5
Parking Attendant
Posts: 15
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posted January 10, 2010 09:45 PM
Engine Swap, Now No Start
Hey all,
I recently bought a 2001 zx12 with a blown motor. It sounded like a spun rod bearing, so I decided to get a replacement used motor to stick in it. I got a motor from a good running 2004 zx12. The only differences that I could tell were the front motor mounts (had to tap new mount holes) the Neutral switch wiring and the stator harness. I switched the wiring from the 2001 for the neutral switch, and soldered the connector from the 2001 for the stator. I put the new motor in with new plugs and tried to fire it up. The first thing that happend was a huge backfire and no start, now all it will do is make backfire noises and still no start. It has a pcIII and it will backfire with that connected or not. any help would be greatly appreciated.
  
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Mauser
Parking Attendant
Posts: 13
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posted January 10, 2010 11:54 PM
Long shot but it's not the fatc the later 12's have a 32bit ECU and earlier models have 16bit ?, not sure what it could affect but just a guess for you.
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tuusinii
Pro
Posts: 1031
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posted January 11, 2010 04:35 AM
The cam and cranksensor are differen on the later 32-bit version ECUs. So You have to change them to the A-model style.
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tuusinii
Pro
Posts: 1031
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posted January 11, 2010 04:37 AM
Well the sensors aren't different but the cam has the pickup at different position and cranksensor has more notches on it...
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Fmyers5
Parking Attendant
Posts: 15
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posted January 11, 2010 08:45 AM
So if I get the sensors from the 2001 and swap them into the 2004 locations (which are the same) then the ecu should start reading thier output and hopefully fire up?
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tuusinii
Pro
Posts: 1031
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posted January 11, 2010 09:12 AM
Yes, but if I'm not remembering wrong You have to chenge whole exhaust cam because it puts the pickup at different timing. I'm sure they changed the cam position sensor from 00'to 01' but not sure abaut the later years but remember hearing it beeing different. Maybe change the crank position gear first and try then, if no go change the cam too...
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Fmyers5
Parking Attendant
Posts: 15
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posted January 11, 2010 09:21 AM
would it be easier to just get the harness and ecu from the 2004 bike? would there be any problems you could see with that? Is it as simple as just getting the harness and plugging it in along with the computer and it should work. Do i need any other harnesses besides the main harness and engine harness? I was just looking at the part numbers from the crank gears from 2001 to 2004 and they are different, would changing them mess with the way the newer motor is set up with ignition?
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tuusinii
Pro
Posts: 1031
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posted January 11, 2010 10:15 AM
it would be much more work because '04 had also dual throttle bodies so You would also need them. I don't see muvh work in changing the crank sensor rotor and the cam comapre to change wiring harness + TB + maybe some others I'm not aware...
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Fmyers5
Parking Attendant
Posts: 15
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posted January 11, 2010 12:09 PM
Thanks for all your help so far! I am going to order a crank sensor rotor off of ebay, it is from a 2000 model bike will that work? also if that doesn't do the trick will an exhaust cam from a 2000 work or will I need a 2001 exhaust cam? Also what all is needed to do a cam swap on a zx12?
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KZScott
Needs a life
high on speed
Posts: 7235
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posted January 11, 2010 04:21 PM
you dont need to change the cam, just index the pickup in the proper location. you may need to grind the nub off of the pickup in order to position the pickup correctly. what you need to remember is to position the pickup for the year ecu that will be "seeing" the cam
only 00 is different. its not the usual change at 02 and up, its 01 and up
____________
01 ZX-12R 8.84 @ 156.3 no bars, DOT tires. Pump Gas, NA.... turbo 8.47 @ 164.
00 ZX-12R 8.62 @ 165.2 no bars, slicks, Pump Gas, 55 shot.... turbo 8.32 @173
00 ZX-12R Fastest NA Kawasaki in the world 1: 222.046 1.5: 226.390 Loring AFB
00 ZX-12R street turbo 1: 227.9 1.5: 234.1 Loring AFB
00 ZX-12R LSR turbo 1: 263.1 1.5: 266.5 Loring AFB Worlds fastest ZX-12R
CMG Racing RCC Turbos
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Fmyers5
Parking Attendant
Posts: 15
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posted January 11, 2010 06:28 PM
So let me get this straight, since my bike is a 2001 in order for it to work properly I only need to change the crank gear from my 2004 motor back to the 00 or 01 crank gear, and do not need to change my cam or cam sensor gear because it is the same from 2001-2005? Currently I have a 2000 crank gear on order (assuming they are the same from 00 to 01) and that is all I should need? I would know if any of this was different, but ronayars.com and my local oem parts catalog are not showing any parts for a 2001 zx12r, otherwise i would just look at the different part numbers. now i am just assuming that the part numbers from 2000 are the same for 2001, with the exception of the cam gear indicator which is the same from 2001 on.
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shiphteey
Needs a job
Posts: 2529
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posted January 11, 2010 06:33 PM
00 has a different cam position sensor pickup.
Also 02+ have a heavier flywheel.
04+ have a 32 bit ECU.
____________
Gemini Motorcycles
Topping out everything from Ninja 250s to nitrous ZX-14s.
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KZScott
Needs a life
high on speed
Posts: 7235
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posted January 11, 2010 07:00 PM
i have never noticed a difference between my crank pos trigger wheel(01) and dads(00)
quick check on part numbers on kawasaki.com show that 00-03 use the same crank pos trigger wheel.
the one pictured for the 04 05 has more teeth.
____________
01 ZX-12R 8.84 @ 156.3 no bars, DOT tires. Pump Gas, NA.... turbo 8.47 @ 164.
00 ZX-12R 8.62 @ 165.2 no bars, slicks, Pump Gas, 55 shot.... turbo 8.32 @173
00 ZX-12R Fastest NA Kawasaki in the world 1: 222.046 1.5: 226.390 Loring AFB
00 ZX-12R street turbo 1: 227.9 1.5: 234.1 Loring AFB
00 ZX-12R LSR turbo 1: 263.1 1.5: 266.5 Loring AFB Worlds fastest ZX-12R
CMG Racing RCC Turbos
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tuusinii
Pro
Posts: 1031
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posted January 11, 2010 11:02 PM
don't you have the blown motor, where You can get parts?
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Fmyers5
Parking Attendant
Posts: 15
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posted January 11, 2010 11:27 PM
No I traded the parts guy my motor for this 2004 running motor, and now Im kinda screwed for parts, so I am ordering the via ebay.
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tuusinii
Pro
Posts: 1031
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posted January 12, 2010 12:44 AM
Ok, I was just assuming You had all the parts from the blown engine.. Anyway just change the cranksensor gear and try. Its easy. Just take the bottom fairing and timing gear cover off and You're there. And personally I think that the cam sensor pickup was changed only because that way You can't get trough 186MPH limiter simply by changing ECUs... So it makes change it being different only on first year. Hope You get it running soon!
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Fmyers5
Parking Attendant
Posts: 15
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posted January 25, 2010 02:49 PM
Well after a little reading, and alot of listening to your guys advice she is up and going. I am going to make a list of things that you need or need to do for a swap 02-05 into a 00-01 frame and ecu.
Need the cam rotor for a 2001
Need the crankshaft rotor for a 2001
You need to drill out the mounting holes on the head
you need the gear indicator sensor from a 2001
you need to switch the ends on your stator, and lengthen your harness
that is all i can think of now, I am almost done
Now i just need a new radiator, and a stator cover for a 02-05 engine
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