'84 1200 engine for a '82 GW

[Denver]

Yes one of the FIRST things stripped off, :Awe: small bits & pieces abound on this year, as well as 83's. :swoon: Rear engine covers are sought to convert cable clutch. Best to try to find one that's intact, or an 1100 to convert with front end, rear end, & drive train, complete to build one. :yes:

 

[ekvh]

I guess I was wrong. You must have to wait for a moderator to do it.

 

[joedrum]

sheesh ...good info 84 1200 takes 1000 covers there just short ... yep 85 up is not so easy .... opcorn:

 

[canuckxxxx]

I think I have the coolant supply for my plenum sorted out now. I used the threaded hole where the temperature sensor screws in. But I had to make an adapter for the temperature sensor threads to 3/8" NPT. So I took another temperature sensor I had and drilled out all the insides. Then I took a 3/8" NPT x 3/8" barbed fitting and did some "machining on the barbed end, with a file, so it fit nicely into the sensor shell. Then I soldered the two together.

Sensor shell on left 3/8" NPT on the right

coolant supply to plenum 2

• canuckxxxx
• Jul 13, 2015

So then I put a "T" and another 3/8" NPT x 3/8" barbed fitting that the hose to the plenum will connect to. The real temperature sensor will go in the other leg of the "T". That part is a little iffy because the sensor sort of screws into the 3/8" T. Hopefully the Teflon tape I put on the threads and the "O" ring at the head of the sensor will seal it up. I almost glued the sensor into the T with JB weld but I realized that I would not be able to screw the whole assembly out because the sensor sticking would prevent a complete rotation.

coolant supply to plenum 1

• canuckxxxx
• Jul 13, 2015

Brian

 

[canuckxxxx]

Hmm, maybe I could JB weld the sensor into the end of the T and have the barbed fitting for the hose go into the T that sticks out the side.

 

[joedrum]

opcorn: hmmmm choices i like choices

 

[dan filipi]

I did it the same way. Trying to remember what I did about the different thread.......I know what you mean, it's just enough different.

 

[canuckxxxx]

So I decided to put the engine in the bike tonight. :builder: I have the engine on a 4 wheel dolly so I hoisted the bike up with chain hoist. Rolled the engine in, bolted the removable frame section in and put the long bottom bolt and the 2 bottom bolts in. Then hoist the whole thing up, take everything away from underneath and lowered the bike to the floor.

image

• canuckxxxx
• Jul 11, 2015

image

• canuckxxxx
• Jul 13, 2015

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• canuckxxxx
• Jul 13, 2015

The right timing belt has lots of clearance to the frame :good:

image

• canuckxxxx
• Jul 13, 2015

Maybe tomorrow or the next day I can try and fire her up. :music2:

Brian

 

[Ansimp]

The temperature sensor requires an earth for accurate readings

 

[canuckxxxx]

Ansimp » Mon Jul 13, 2015 8:07 pm[/url]":1pwia6ld]
The temperature sensor requires an earth for accurate readings

With the Teflon tape and Orings I may have isolated it. :doh: ..will do ohm reading tomorrow.
Thanks for the heads up. :thanks:

Brian

 

[canuckxxxx]

It lives! :Egyptian: :music2: Got it all together yesterday afternoon and it fired up right away...after I figured out that the kill switch was in the off position (fools me every time :doh: ). It actually runs pretty nice, idles good, revs up, no leaks so far.

I let it run until the fan came on and shut it down. I am going to re torque the heads this morning and then take it for a test ride.

There is, at least one problem: The centre stand will not go all the way up because it runs into the left muffler because it is wider apart than with the 1100.

centre stand

• canuckxxxx
• Jul 15, 2015

Would a 1200 exhaust fit in closer to the frame?

Getting close
Brian

 

[joedrum]

yep that 1/4" is in play LOL.....bend stand

 

[slabghost]

Maybe a 1200 stand would fit? Not sure but My 1200 is a lot easier to get on the center stand than my 1100's are.

 

[joedrum]

did you knotch pistons or did the 1100 cam clear everything brian ? opcorn:

 

[canuckxxxx]

joedrum » Wed Jul 15, 2015 5:38 am[/url]":123sir38]
did you knotch pistons or did the 1100 cam clear everything brian ? opcorn:

I didn't touch the piston tops. I put 1/8" of plumber's putty on top of piston where valve relief is and the 1100 intake valve didn't even make a mark on it.

 

[joedrum]

wow ...must be huge difference from 1100 cam to early 1000 cams ... be interesting to see how this motor works .... opcorn:

 

[slabghost]

Glad it's running Brian. ATF in the fuel it just get's better

 

[canuckxxxx]

Joe, maybe I didn't do it right but I put the putty right where the intake valve cutout is and I turned the engine over and no marks. And with the fact that the engine turned over without hitting anyway, I said good enough.

Slabghost, I will definitely put ATF in the gas.

OK, went for about 1/2 hour ride that included some freeway. Bike ran nice and clean. Power is about on par with when it was an 1100 so it is quite rideable. No leaks so far. Taller 5th gear: 3300 rpm at 60 mph vs 3700 rpm at 60 mph as an 1100. So that is nice.

Did another compression test when I got home:
1 - 132
2 - 135
3 - 136
4 - 136

Brian

 

[canuckxxxx]

I would also add the it seems to be mechanically quieter than the 1100. Also, there are no ominous knocks or ticks from the bottom end so far.

 

[joedrum]

hmmmm surprised ... i would have thought big difference ....hmmm this brings a lot to the table on 1200 mod bikes ..... yes the 11% more oil flow in 1200 quiets the motor down a lot....it also has the stoutest crank and primary chain set up .......great work brian opcorn:man this bike has been though some changes now :Egyptian: :hihihi: