Project Motor Swap

[Old Rider]

Installed the starter drive.

Twice.

See why?

[Old Rider]

Yes the C........R...   
Thanks for sharing you rebuild nice picks !

[FJ1200W]

Yes the C........R...  
Thanks for sharing you rebuild nice pics !

Yep! You got it.

And my pleasure, thank you!

[FJ1200W]

Installed the starter drive.

Twice.

See why?

Yep

That's exactly what I did.  

And I had to make it that way, which is even funnier.

Easy enough to correct.

It was satisfying when the upper case dropped right into place.

I have to admit, that upper case is heavy when assembled. I was able to do it alone, but next time I'm inviting a buddy over.

Fun fun fun!

[FJ_Hooligan]

Too old for tests.  Care to clue in the rest of us who haven't been that far?  Not much of a lesson if you keep it a secret.

Does it have anything to do with that pin?

[RPM - Robert]

Does it have anything to do with that pin?

no, the rods are not in the holes for the cylinders, they are laying on the case split line.

[Pat Conlon]

Hey Steve, thanks for the great write up.

Question: On your earlier post (Reply #67) with the picture of the shift forks, *I think* the caption is reversed.
The later stronger shift forks are on the left and the early skinny weaker shift forks are on the right.
Late (Left) to Early (right)



,,,I think....

[FJ1200W]

/quote]


No Sir, the longer ones are the newer ones.

Better leverage I assume - Robert/Randy???

/quote]

I can relate. Robert beat me to the answer. thank you Robert!

Ironically I picked the crank up a second time to pull two of the rods out. I was used to working with it in the lower case. Lesson learned - Third time was the charm.

While assembling today, I found a few parts that I failed to order or just went missing. I order those up, along with a oil filter adapter.

I noticed the gearbox did not shift smoothly. It would not go into all of the gears.

And that the shafts did not rotate as smoothly as they should.

Something was wrong.

The shift forks were checked from the bottom, I can see how they could be replaced with the engine in the bike.

Nothing wrong there, I put a lot of thought into it and decided to split the cases again.

I found I had the 1st gear wheel in backwards.

Transmission shifted slick as a whistle!

When I pulled the cases apart the 2nd time, the little o-ring between the cases came out with the upper case. I remember finding it in the upper case, I'm sure I put it back where it goes.

Shit.

I'm pretty sure I did.

I did get the cases back together, transmission spins nicely, as does the crank, no worries there.

Way past my bed time.....

Thank you all for your replies

[FJ_Hooligan]

The mention of only the starter drive threw me off.

[FJ1200W]

According to a text from the USPS, a shipment from RPM to me is due today.

I'm excited to move on to whatever comes up next.

[FJ1200W]

Taking my time assembling the engine.

It was a challenge to safety wire the oil pump, have a look, if I need to tear everything down again, that's what I need to do.

Clutch: The original steel wire was in place, along with the spacer and different clutch plate. If memory serves me right, I can just replace these with a full plate, correct?

The oil pump gear seemed loose, I don't remember it feeling kind of "wobbly" - is that normal? When assembled with the drive gear and clutch basket, it felt snug.

What else - I found the oil level sensor was removed and a special plug made.

And the neutral indicator guts are missing.

Luckily I have a complete parts bike.

Other than that, everything is pretty straight forward.

My plan is to keep assembling and when I get to the block, measure the deck height and make a determination on base gasket thickness.

I'm going to look through some boxes for a fork seal for my '89. I know I have one somewhere......

If it rains money, I'll order the kit

https://www.rpmracingca.com/proddetail.asp?prod=M%2FC%3AFJ41ForkR%2FBKit

Thanks in advance for any and all assistance

[FJ1200W]

I remember making this diagram and now I remember I forgot to include what the color coding was......

I'll keep looking.......

[Pat Conlon]

I remember making this diagram and now I remember I forgot to include what the color coding was......

I'll keep looking.......

Steve, I used your colored diagram (thanks again) on the Slipping Clutch post over in the Clutch Files section.
Scroll down... http://www.fjowners.com/index.php?topic=1808.0

[FJ1200W]

Steve, I used your colored diagram (thanks again) on the Slipping Clutch post over in the Clutch Files section.
Scroll down... http://www.fjowners.com/index.php?topic=1808.0

If it was a snake it would have bit me!

Thank you so much, that is exactly what I was looking for!

Oh - Thanks again for thanks again

[FJ1200W]

Decided to split the old cases one more time.

I'm glad I saved the box for the bolts.

The o-ring in the center was right there where it was supposed to be.

Triple checking everything else.