Ask The Editors: Vintage Suzuki ATV Engine Swaps
The answer to this question isn’t quite as cut & dry as we would like on account of the fact that it really depends on how far you are willing (or comfortable) to take the modifications necessary. If cutting frame members and re-welding them is within your mechanical range as well as crafting motor mount tabs, the sky is truly the limit.
In terms of minimal chassis modification, we have heard the closest fit is the Honda 300EX mill, another manual clutch, air cooled four stroke engine. Our sources tell us the most difficult part of the swap is the electronics, particularly putting together recesses to house the electric starter components of the 300EX and battery.
In terms of some of the more labor intensive swaps, forum member kawasuki500 has successfully transplanted a Kawasaki Ninja 500 2-cylinder street bike motor into an LT230S that he estimates is good for 50-60 horses (photo above). Perhaps contacting him for specific details on the swap will net deeper insight into the process.
We’ve also tracked down a Youtube clip of an LT230 boasting a GS450L motorcycle engine here:
Truly it appears the options are limited only to your imagination/ limitation of your mechanical abilities or budget.
