Scarlet's resurrection

[GLoweVA]

Okay, now that I've got all the parts on order for her engine transplant, it's time for me to start the thread documenting this so that anyone can read this and see what it's like to do an engine transplant.
I'll take plenty of pics along the way to document it.
For Starters,
I went thru and the donor engine and checked all the electricals. (starter, pick up coils, neutral switch, alternator stator and rotor)
Then I went and pulled the plugs and turned it by hand. Okay there. (#2’s hole had some plug thread problems, but I think I’ve got it worked out now)
Put jumper cables to it and turned it with the starter and the compression numbers were way up there, like 130ish.
Pulled the plug for the middle gear and level is fine and oil looks new.
Since it’s an 81 engine, I had to pull the mechanical advance of my SG and put it on the donor.
I’ve got to pull the remaining exhaust studs out in preparation for the new ones coming.

I’ve disconnected all the plugs off my SG and I’ve loosened the engine mounting bolts. (Had to use my breaker bar for some of those suckers)

[haywardguy929]

Thanks for doing that, I need all the education I can get. Much appreciated.

[MaximPhil]

Hi George,
BEFORE pictures have to be taken at the begining of the project
Please include accurate temperature and other weather related info in your
"workshop" aka "Windswept carport" Also accurate notes of Hindsight will be useful for future generations
Good Luck and keep smiling.
Phil

[GLoweVA]

I begins

Alright Phil, here's the before pics:
The Donor Engine. '81 (Thanks TC!!)

The SG:

I took the oil filter cup off because most here says it helps. It sure did because of where I put the 2x4's
Here's the front 2 motor mounts out and the jack under it. I used 2x4's to support the engine:

I had to disconnect the 4 bolt flange on the output shaft of the middle drive. The boot was hard to hold back.

I had to prevent the rear wheel from turning. Those nuts were TIGHT!

I pulled the rear mount bolt and I forgot to make sure the boot was not interfering with the flange and I ended up tearing it a little, then I made sure that the boot was clear.

Here you can see that the 2x4's provide enough clearance so the the engine will come out the right side.

Just gently ease the motor out the right side, keep an eye on the 2x4s and make sure the weight is distributed okay.

I used the jack and it's wheels to help ease things out. I wish I had used longer 2x4s and a couple to put under the ramps to make the heights even out some.

Here's the old engine out.


I had a little bit of a hard time getting the old engine down to the ground and the new engine up on the jack, but I found the sweet spot and balanced it okay and then got the new engine up on the ramps ready to go.


Sunday (Easter) should be a day of rest, but it'll be my first day off in 3 weeks.
Unfortunately, there's rain in the forecast, but maybe it'll hold off until the afternoon.

[MaximPhil]

Hi George,
Keep up the good work
Phil

[Petersg_99]

Hi George,
Keep up the good work
Phil

+1 Thanks for the pictures...

[cpmaynard1980]

Your pics make it look so simple. lol. Maybe I should do that have my frame repaired.

[GLoweVA]

Your pics make it look so simple. lol. Maybe I should do that have my frame repaired.

Hey Charles, It wasn't THAT simple.
I did do a LOT of reading here about how to do it and since TC brought the ramps by I decided it was time to get off my butt and do it.
The trickest part, (and I should have had some help on) was getting the engine to rest on the ramps/boards and then getting the engine to the ground.

Like I said in one of the captions, I should had been more careful about that middle drive boot. I did end up tearing it, but I think it'll still work okay.

Now I've got to get motivated to get the new one in.
To bad this weekend is a bust, so it'll have to be next weekend.

How's your bike coming along? Planning on fixing the frame, or just cleaning it up? Got those gears done? TC, me and/or John will help if we can, just ask.

[Nightengale]

nice thread

Good thread, way to pass on the knoowledge. Let me know iif you need a hand with anything.

[cpmaynard1980]

Thanks GLoweVA. No sadly I havent done much besides a few little things here and there. Time and money have been low with every thing else going on around here.

Its stripped down a little more. At one time I was going to part it out but I ended up getting the title for it. Still have all the parts.

the more I look at it the more I want to do something with it but I keep changing my mind on what way i would like to go with it. lol

[TopCatGr58]

Hey George,

John/Nightengale will probably be a little late tomorrow, we got a lot done on his bike today but not all of it.

Drained engine and final drive oil, pulled battery, swapped on old handlebars for the flip, removed oil cooler adapter/radiator, pulled gas tank, carbs, clutch basket, tranny pan, countershaft/gears.

Inserted pre-ground gear set, reinstalled oil pump with new O-ring, put in slightly used clutch frictions(~2.95+mm vs. old 2.85-2.9mm, new HD springs, deglazed steels), cleaned/regreased clutch throwout bearings, installed tranny pan, shift cover, clutch cover. Also installed SOFA, letting it CURE overnight. Installed oversized self tapping oil pan bolt/combo drain to repair stripped threads.

Pulled both wheels, replaced both tires, balanced, reinstalled, then flipped bike ride side up, reinstalled good handlebars.

Tomorrow we'll reinstall Battery, carbs, throttle cable, gas tank, refill with OIL, final drive oil. Then take a short test ride.

T.C.

[GLoweVA]

almost done

Sunday, while waiting for John to come by, I put on the saddleman seat cover and went thru the carbs one more time. Last week I put the new diaphrams on the slides. I got new allen cap screws for the carb tops at Home Depot for $.89 for 2. (most of my phillips screws were buggered up)
John got here and we put the engine in and tightened down the mounting bolts.
Then we put the headers/mufflers on.
Torqued the middle drive output bolts.
I pulled out the old CCT and put in the ACCT from the bad engine.
The Honda VF coils are a direct fit up and are now just waiting for the red NGK plug caps from England.
Put a new filiter in and put 3 qts of oil in.
Here's a pic of my status:



Also put my old battery on the charger.
Ideally I want to bikes ready to ride. (just in case one breaks down, I can hop on the other)

What's left?
Mount the carbs, bolt up the air box.
Mount the coils and put plug caps on.
Finish putting the wiring back together (solenoid)

[GLoweVA]

Update: Almost DONE!

SO today, I got out there and tried to finish her up.
Went to hook up the starter solenoid and found out that the 81 engine/starter lead only has the one wire, whereas the 80's had another lead for the ballast bypass circuit.
I clipped that lead off the bad engine and crimped on a lug and that'll take care of that.


Swapped carb boots over too. I didn't like the looks of the ones that were on the Donor.
Put the clutch cable into the clutch and adjusted as best as I could.
Got the old battery recharged and back in and put my tender lead on too.
Brake light cover back on.
I decided to go with the headlight and signals for now and then later swap over the WJ later.
Put the carbs in and tightened up all the boots and air filter in also and new fuel lines too.
The seat cover is just drawstring tight right now, later I'll get it tighter and use the stab fork tabs to make it permanent.

Here she is all put back together ready and waiting for those NGK plug caps:


THE POLLEN.... Save us from the POLLEN.
She's so dirty....

After I get that engine running and tuned up, then it's cleaning time.

[DGXSER]

You made quick work of that!! Looking like a nice pretty bike again soon!!

[GLoweVA]

Like everyone here says, an engine swap is really a lot easier than trying to tear an engine down in the frame.

Last time I did that with the G and it's piston swap, it took me many months.