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Discussion Starter #1
What year 650 burgs are compatible with a 2003 complete engine / powertrain ? When I say compatible , I mean plug and play no re-wiring or re-plumbing . Also , is the CVT and or clutch compatible with other years ?

Thanks .....TheReaper!
 

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If you don't want to change anything, just plug it in then 03-04. Past that you start getting into changes in the ECM and throttle bodies that are going to require other things to change. Even between the 03 and 04 there was a wiring harness change so you may run into some minor differences.
 

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As far as I know there were no changes in the clutch from 2003 to 2012 so any should fit.

Others have reported that the late model CVT's will also fit the early model bikes but you will have to change the primary input adapter.
 

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Now if you go with just the base power train and reuse things like the throttle bodies off and a few other bits off your 03 then you can probably use any year.

Swap out the wiring harness, dash, ECM and ECM mount to match the year model power train and you can also probably make it work.
 

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What year 650 burgs are compatible with a 2003 complete engine / powertrain ? When I say compatible , I mean plug and play no re-wiring or re-plumbing . Also , is the CVT and or clutch compatible with other years ?
2003 and 2004 use separate engine and CVT controllers vs the 2005-up.

The 2003 and 2004 CVT use an adapter gear that bolts onto the primary shaft vs one on the outside. The CVT's are compatible with 2003-2012 as long as you remove the 2003-2004 adapter.

The clutch should be interchangeable with 2003-2012.
 

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I have not looked at a newer Burgman all naked but I am sure that if you pull the 03's engine module and remove all the 03 sensors/relays and bolted a 08 engine module in a 03 frame using all the 03 sensors/relays/wiring/ECM/throttle body it should work. But I am not 100% sure and do not know if anyone has tried.
 

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I have transplanted a complete engine / drive train unit from an 08 to an 03. The only component that caused me any challenges were the throttle bodies (which had different electrical connections). I resolved this by simply replacing the 08 throttle bodies with the old 03 ones - I did this 3 years back and everything has being running fine since then.

I have no doubt that you could also do this in reverse but I question the wisdom in replacing the stronger 06+ primary pulley adaptor / primary driven gear combo with the older weaker version.
 

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I have transplanted a complete engine / drive train unit from an 08 to an 03. The only component that caused me any challenges were the throttle bodies (which had different electrical connections). I resolved this by simply replacing the 08 throttle bodies with the old 03 ones - I did this 3 years back and everything has being running fine since then.

I have no doubt that you could also do this in reverse but I question the wisdom in replacing the stronger 06+ primary pulley adaptor / primary driven gear combo with the older weaker version.
I'm assuming you are using the 03 ECM.
 

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Discussion Starter #9
2003 and 2004 use separate engine and CVT controllers vs the 2005-up.

The 2003 and 2004 CVT use an adapter gear that bolts onto the primary shaft vs one on the outside. The CVT's are compatible with 2003-2012 as long as you remove the 2003-2004 adapter.

The clutch should be interchangeable with 2003-2012.
And that would be ADAPTER,SEC FIX part # 21855-10G00 , if so that is just removed and it's plug and play with other models ? I'm asking because I just picked up a 2003 rolling chassis that's been sitting in a police warehouse for ? Long story short , guy bought it at police auction , couldn't get title , used plastics and a few other parts then sold it to me a few days ago . I am going to tear it down and part it out . It's not that I need the money I just want to become more familiar with these 650's . I've only spent a few hours on it so far and I feel like I've already learned a lot . I've only worked on simple scooters like he Honda Big Ruckus , a little on a Silverwing etc . but nothing ever like this . This has been interesting to say the least .

TheReaper!
 

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And that would be ADAPTER,SEC FIX part # 21855-10G00 , if so that is just removed and it's plug and play with other models ?
I didn't look at the part but yes if the adapter is removed and the later one used the CVT will fit up to a later model engine assembly I do not believe any of the CVT connectors changed.
 
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