Engine Swap series....

Kerry · January 21, 2005, 11:22:46 PM

Month-old gas should be OK. If you're suspicious of the petcock, consider running the front fuel line from the fuel tank petcock straight to the lower T-connector between the carbs.

This would be just until you get the engine running ... you can reroute the hoses later and troubleshoot that stuff separately.

TeBo · January 22, 2005, 02:15:49 AM

I'm not suspcious if the petcock is broken or something. If it worked w/ my old engine, it should work now. It's just that, I noticed 3 holes on the front side of the petcock (and one hole in the back.) but I don't know where that 3rd hole goes. It's not in the diagram you showed me, nor is it on the sticker on the bike...

Kerry · January 22, 2005, 10:11:49 AM

All of the (non-CA) fuel hoses should be shown / labeled / described on my Fuel Hose Routing page.

The diagram at the bottom of the page CAN be misleading because of the way multiple hoses visually overlap at the angle it was drawn at. If there is a question about something in the diagram, go back to the text and photos at the top of the page and mentally connect the hoses to the "holes" as described.

The short, farthest-left "hole" you describe from the petcock sounds like the inlet for the ON hose. The other end of the ON hose attaches to the shorter, rear-most outlet of the fuel tank petcock.

TeBo · January 22, 2005, 10:47:53 AM

kerry, sent you an email w/ the picture of what I'm curious about. thanks

Kerry · January 22, 2005, 11:25:37 AM

Now I see the problem. When you said

Quote from: TeBoI have a strong feeling that it has something to do w/ the opening on the petcock that I don't seem to know where it goes. If I was sitting on the bike, it would be the one front side, to the farthest left (smallest opening.). . .

You meant "to the farthest right" then ... right? This one on the back? (Haynes photo) :dunno:

The unconnected "hole" in the photo is for the vacuum hose. If that hose is not connected, or there is a hole or rip in the hose, then you will have fuel delivery problems when the fuel selector switch is turned to the ON or RES positions. That's because the petcock will not allow fuel to flow in those positions unless it receives vacuum impulses from the left carburetor. And THAT is so there will be very little risk of a fuel overflow when you park your bike.

Back on my fuel hose routing page: Read through the 4th bulleted item at the top of the page. Since GRU didn't label the vacuum hose in his photos I resorted to a verbal description to go along with the pictures. The hose should exit the petcock, come up between the carburetors, and attach to the vacuum port on the front right "corner" of the left-side carburetor.

Assuming that the rest of the hoses are hooked up right, you should be able to run the bike without the vacuum hose by turning the petcock to the PRI position (which allows fuel to flow due to gravity rather than vacuum impulses). However, without a vacuum hose in place you would want to cap the vacuum port on the carburetor.

EDIT: Perhaps one more diagram would be helpful. Look at this one from BikeBandit. Item 53 is the vacuum hose - the diagram shows approximately where it connects to the left carburetor.

TeBo · January 22, 2005, 09:32:32 PM

also, how many turns should the fuel needle be turned?? I just realized I haven't even touched the fuel needle from the new carb, therefore it could be all the way up or all the way down for all I konw. Thanks tho.. I get it now, I think I had put that hose into the fuel pump instead of the petcock.. maybe that was where I'm starting to go awry in my diagrams.. (Dag nang asian kid... learn hwo to read blue prints :guns:

)

Kerry · January 22, 2005, 10:58:47 PM

Now you're confusing ME. Fuel pump?

Hopefully Srinath or another carb expert will come along and answer the "fuel needle" question. I still haven't fiddled with mine....

TeBo · January 23, 2005, 01:28:40 AM

sorry kerry.. I meant the "Canister"?? as it's called on the sticker under the seat

anyways, gave it a good 3 hrs earlier. Seem to ahve all the hoses down right. Everything was properly put in. started it up, and she wound up, but died right away. so I'm guessing I have a few thigns right so far. That wierd noise is killing me tho. I don't know if its supposed to do that. It's like a sound comming from a coffe can being shaken w/ a plastic ball inside it or something. I checked the pistons through the spark plug holes (took the spark plugs out, then started it, and checked if the pistons went up and down.) and they did. So good sign. . . Anyways, I'll try again prolly tomorrow night or something.

ONE WIERD THING: After a while of trying to get the bike to start, I noticed smoke comming out of the small hole in the bottom of the airbox. anyone have any idea what that could be??

more fun: AFter a while, I just started taking a break, then went to my garage and took apart the old engine to see what was wrong w/ it. Took the top part off, opened the cams, and everything seems fine. Took the head off the longbolts, and WHOOOWEEE ! ! ! ! Right side piston was not only stuck in the sleeve, connecting rod is gone, and left side piston looks burned. I look inside the block, and see chips of metal everywhere. whoa fun. Now I feel stupid for still tyring to think that it could still run. . . hahah.. anyone want parts off an engine?? (taht I still have that seems ok.)

Bluknyte.. I might have that top part you wanted. I'll PM you.

chbix · January 24, 2005, 12:18:53 PM

Hey tebo, I was talking to my brother and he says that he remembers there being a screw loose down where the ignition advancer is (inside the cover, that may be the rattling you hear. Im glad to hear that the install went ... "ok". Hope you get it started soon, sounds like your close.

chbix · January 24, 2005, 12:20:29 PM

I didnt notice where you mentioned it, but did you change the oil before you tried to turn it over? I know I did not change it in the 2 or so months it sat in the garage, and I have no idea when or if the guy before me change it.

TeBo · January 24, 2005, 09:24:30 PM

yea, I changed it to Quaker HiPerf 10W30 oil. I drained out the old oil. . . I talked to a mechanic and he said "Dude, well, it sounds wierd, but it doesn't sound like something you should worry about. Unless you hear a wierd loud sound that stops the engine man, well, dude.. Give it a go." So I guess it's ok for now anyways. I have a new plan: Take apart the old carb, just to see that I can and put it back together. Then, I'll take apart the new carb, and clean it out. I think it might just be that...

TeBo · January 24, 2005, 09:36:25 PM

I jus tnoticed. Thanks kerry, for that diagram of the carb from bike bandit. Should be a great deal of help pulling apart and putting together that 64 pcs. puzzle (as it seems.)

dane_lindsay · January 25, 2005, 12:10:58 AM

haha "dude, give it a go" typical. robert pirsig was right

TeBo · January 25, 2005, 09:34:16 PM

Quote from: dane_lindsayhaha "dude, give it a go" typical. robert pirsig was right

Who's Robert Pirsig??

Kerry · January 26, 2005, 12:04:23 AM

Quote from: TeBoWho's Robert Pirsig??

The author of Zen and the Art of Motorcycle Maintenance.

dane_lindsay · January 26, 2005, 01:05:01 AM

lll

TeBo · January 28, 2005, 02:06:32 AM

ok, looked over everything.. Still no go.. Last thing I could think of is the Carb.. I'm gonna try to slap the old carb on, see if it works.. if it does, then Imma take the new carb to the shop and get it worked over (cuz I can't do carbs for shiznitz.)

TeBo · January 29, 2005, 12:35:07 AM

SHE's ABOUT TO START ! ! ! I. . . COULD... TASTE IT ! ! ! well, ok, not taste it, but I could feel it.... It seems like she wants to turn over. . . I guess there's just some sort of clog in the system that it's trying to burn out or something. Could it be because maybe there might be oil in the cylinder? or is that normal?

Anyways, I'll charge the battery back up overnight, and try again in the morning (Day off.. woohoo! ! !)

Someone told me to put half a teaspoon of oil in the engine, so I put it thru the hole of the spark plug.. I'm guessing I might have messed up on that one huh? anyways, let's pray for tomorrow...

Kerry · January 29, 2005, 12:45:56 AM

Quote from: TeBoSomeone told me to put half a teaspoon of oil in the engine, so I put it thru the hole of the spark plug.. I'm guessing I might have messed up on that one huh?

Sounds right to me.

Good luck, and let us know how it goes.

The Buddha · January 29, 2005, 01:38:15 AM

Quote from: TeBoSHE's ABOUT TO START ! ! ! I. . . COULD... TASTE IT ! ! ! well, ok, not taste it, but I could feel it.... It seems like she wants to turn over. . . I guess there's just some sort of clog in the system that it's trying to burn out or something. Could it be because maybe there might be oil in the cylinder? or is that normal?

Anyways, I'll charge the battery back up overnight, and try again in the morning (Day off.. woohoo! ! !)

Someone told me to put half a teaspoon of oil in the engine, so I put it thru the hole of the spark plug.. I'm guessing I might have messed up on that one huh? anyways, let's pray for tomorrow...

Oil in the cylinder is great ... yea ... but do not crank it over with the spark plugs in ... guess they forgot to tell you that ... you crank it over wihtout the plugs so the oil gets everywhere, and most of the oil will come flying out the plug hole ... yes get your eye in there ... oil at 60 knots = fun ... then you may want to put a wee bit of gas in there and crank again but do that just before trying to start ... basically the chamber should be free of oil and have almost no gas as a liquid in it either ... Any fluid in there causes hydrolock ... fluid wont compress and you are trying to get it to compress ... Bad ... anyway just before starting the gas should take out the oil and leave very little gas that first try that gas will light up and act a bit like starting fluid ...
Cool.
Srinath.

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Engine Swap series....