Stafford Springs Motorcycle Swap meet

A very lackluster turnout in Stafford this time. I have never seen such a minimal turnout for the swap meet.
Did see a couple of old Harleys:

And a possible frame for Mark....

On the road again

The bike appears to be running fine, minus my brain fart for wondering why the bike would not start while it was in gear .... duh...
I am now gassed up and ready to go:

Day 14 and Day 15- Kawi engine startup preparations and startup

Well, I took the final key steps to starting the bike on Saturday. I made the remain electrical connections, bled the clutch and put on the tank. I also took the time to put on the new exhaust. This required scrounging for some rubber grommets and fasteners at Autozone to connect the exhaust in a position behind the passenger peg. [There's a couple more hours.]

 Today, I hooked up the battery and rolled the motor a few times to get the oil circulating. Then I connected the spark plugs and she fired right up.

Then my wife says 'hey, what is that bolt that just fell on the floor under the bike'. My heart went THUMP, THUMP, THUMP.


I turned the bike off and said oh-crap, because it looked like a rocker cover bolt... Turned out, it was just the bolt for the one shift pedal I had loosely slipped on. Thank God. I started the bike back up and let the motor heat up until the fan came on. I have not yet heard any ticking noises from the motor. Hopefully it will stay that way.

The new exhaust has a slightly higher pitch then the duals... and there a little louder.

Test ride this afternoon.

Day 12 and Day 13 of the Kawi engine installation

So, I am nearing the end ( I hope ) of this project.

On Day 12, I did the initial connections of the engine to the bike. This entailed doing some of the tougher connections that could be done with the engine nearly in place but not quite, so I had room to work.
First, I started connecting up the throttle body.... throttle connections, vacuum hoses, etc

 and connecting up the water lines.

Then connect up the transmission.

Then attach the motor mounts.

Another hour working on the bike.

Then I start Day 13 and connecting almost everything.
The thottle ...

The lower frame.

Lower electrical connections....

 The horns ...

The switch and choke ...

air cleaner backing plates

 The radiator ..

And now I am so close. I need to bleed the clutch before I can close up the left side, and I have a couple of lines for the gas tank and then I can put on the tank and put in the fluids.

And that is a 2 more hours down. At some point I will add these hours all up for the job.

Day 11 - Kawi engine installation begins

I went out to the garage for an hour and raised the rear of the bike a couple inches so that the rear tire was definitely off the floor and I had some room to work with the motor.

Then I rearranged the motor on the lift so that none of my blocking would be in the way and removed the oil filter. Then I slid the motor mostly in place and did a little blocking to help keep it there for the next phase of starting the throttle connections.

Day 10 - Kawi engine assembly

Well, another evening to button up the engine in preparation for the install. Put the airbox cross-tube in and prepare for the throttle body.

 

 I changed out the seals. That was a good time. It took me a while to figure out the right way to do this.
Then I put on the brackets for the air cleaners.

Put the plugs backing in for checking the timing.

 

 Start making some hose connections for air control switches.

I think we are ready to go. 

 This was another 2.5 hours. The engine is ready to be connected up to the bike.

 Next time we will slide the engine into place and start connecting up.

Day 9 - Kawi engine assembly

Put in an hour today, and closed up the front cylinder.
At least it was something.

Day 8 - start assembling the second cylinder

So, on Friday evening I tried to complete the second cylinder, but I kept getting interrupted. I did manage to disassemble the the rocker box and do some cleaning.

I did the same steps before, using the compressor to blow out the rocker shafts and rocker arms. I did not encounter anything unusual.
I assembled the rocker box onto the head. That is as far as I got.

Another 1 put into the job.