2003 sportsman engine swap
 

I picked up what I originally thought to be a 1997 sportsman 500 which needed a new engine. I bought a used engine from a '98 to swap over, but now I think my machine is actually 2003. I have a number of questions:

1. How can I be sure of the year? (there is nothing on the front fender area).
2. Will a '98 engine easily swap over to an '03?
3. What about the electrical components?

Thanks for any help you can give me!

find the vin# and you'll know the year of it. it might be onthe front end if not it should be stamped into the frame of it maybe up under the fender on along the frame some where. i think an 03 ' would a differnt generation bike then an 98'. just a guess

this site on the first few pages of the pfd will tell you how to read the vin# and where to find it and tell you differnt generation models.
http://www.dealerorders.com/manuals/..._reference.pdf

Hi I am sorry I cant help with your situation but I noticed that u have an engine that might not be able to be used. If that engine doesnt work for you let me know and maby I might be able to use it if you sell it to me for the right price. thanks for your time and good luck with the bike.

Thanks for the information, I'm now about 90% certain I have a 2003.

The '98 engine bolted right in and looks identical, with the exception of the electrical components. I'm not sure how if I'll be able to hook the engine up to the existing cdi, coil, etc. Or if I'll have to transfer all of the '98 electrical parts over. Any help would be greatly appreciated, I'm really clueless when it comes to the electrical side of engines.

I think I've come up with a possible solution. Would it work to just place the stator from the '03 engine into the '98 engine? That way the cable connectors would all plug right in. Also what are the differences between the '03 HO engine, and the '98? I know the carb is bigger, but is anything else different?

i am guessing but beleave the timing might be differnt as well as the cam. not sure if it would work w/ the cdi/stator. i'll give a cross check.
i would say no as everything is differnt and it looks like only 97'-98' was the only years they fit. imo.

What do you mean by "everything is different"? Are you talking about the internal engine parts, or the electronics of the HO?

So if I wanted to swap over my '03 HO stator, it would have to go into an HO engine, correct? I'm looking at a 2000 HO motor at the moment, would it work in that?

my 96 is the same besides the rear end cuz they went to CV's compaired to my 09..both are 500HO's

The 500 Fugi motor is the same from when it came out in 96 and todays 2009. The only thing different is a high duration cam was added in 01, there are 3 different fuel delivery sytem for the motor
a 34mm carb,40mm carb(H.O) and a 39 mm throttle body, EFI .

Did you get the 40mm carb with your 03 motor,if not you can use the 96's 34mm card. Not sure if it may need to be rejetted for the 03's Higher Duration cam but thats not big deal. You just have to swap the 96's smaller carb intake ADAPTER (#30 in pic below) over to the 03 motor to accommodate the smaller 34mm carb.

Other than that all 500 fugi motors are a straight swap.

http://images.powersportsnetwork.com...0_3609D003.gif