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Old 12-03-2012, 04:28 PM   #1
Bandit101
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Default Bought a basket case winter project

Got the new jets installed and tuned the carb. Took bike for first test ride and everything seems OK. Amazing how quickly this project came together. Guess I will have to find another winter project now.


Current progress Up date. Well the engine is installed and today I started it up. Amazing how smooth it runs. I'm impressed. Came with the V&H Longshots and they really sound good. Have not done the road test yet, still finishing up odds & ends but progressing much better than expected. Look below for pictures with engine installed.





Early last week while scanning the adds on Craigs List, I came across an add for a 2004 Kawasaki 1500 Vulcan Classic. 30K, engine had spun a bearing, been sitting for 2yrs, $1000, OBO. So I call the guy up, find out he is only 75miles from me, he describes the bike as excellent shape, never down, been stored in his garage since engine went out. Seems he was on a trip to Va from NC when bike lost oil to rod bearings and burnt the bearings and ruined the crankshaft. Had it towed to a dealership where they tore the engine down and told him it would need a complete rebuild. Said he was never able to come up with the extra money to have the repairs done and finally decided to sell it. Told him if it was what he described I would pay the full $1000, and be there Friday morning. So with cash in hand and trailer in tow my trusty GPS took me straight to his driveway Friday morning. It was as he described and I brought it home.
Now some of you may know I previously had a 1999, 1500 classic that the POG failed in and I replaced it with a JOG. Worked fine except for a constant engine whining. Being skeptical and proactive I purchased a 2002, used engine, tore it down, rebuilt and kept it for a spare. Last summer I bought a HD Ultra Classic and since I wasn't riding the Kaw anymore my son took it over.
I still have the spare engine I rebuilt and now have a bike it should fit right into. The one question I do have, is the original engine from the bike has a single stator charging system and my replacement engine has a dual stator.
Does anyone know if these are paralleled in the connector, or do they have seperate connection plugs?
Here are some pictures of the project.








Last edited by Bandit101; 01-01-2013 at 10:58 AM. Reason: update
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Old 12-03-2012, 07:22 PM   #2
sfair
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The two systems run in parallel....a poor set-up that incredibly gives little trouble.
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Old 12-03-2012, 07:26 PM   #3
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Quote:
Originally Posted by sfair View Post
The two systems run in parallel....a poor set-up that incredibly gives little trouble.
Thank you. Should be an easy installation then.
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Old 12-03-2012, 07:33 PM   #4
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I also noticed the pistons are stamped .05m. Is this an oversize? Seems strange for a
low milage motor.
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Old 12-04-2012, 06:57 PM   #5
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That'll be a nice project and it'll be awesome when its done. I'd like to get my hands on a project bike but alas I don't have the time or money.


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Old 12-05-2012, 10:46 AM   #6
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Quote:
Originally Posted by Bandit101 View Post
I also noticed the pistons are stamped .05m. Is this an oversize? Seems strange for a
low milage motor.
It would not be out of the realm of possibilities ( besides all other possibilities)that the piston was factory installed to correct for machining errors, or the piston is mis-marked. Measurement would tell the story.
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Old 12-05-2012, 03:38 PM   #7
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Today I measured the pistons and they are 4.020. They are manufactured by ART.
Seems someone had previously been into this engine. I am surprized the crankcase
main bearings are perfect, considering the condition of the rod bearings.
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Old 12-05-2012, 03:48 PM   #8
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I cannot see the crank being salvageable with those rod bearings.
The case mains "measure" OK?
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Old 12-05-2012, 04:11 PM   #9
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You are correct, the rod journals were beyond any repair. For some reason the owner wanted to keep it as a momento. Yes, the case mains measure good.
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Old 12-11-2012, 06:34 PM   #10
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Check the updated pictures. Engine installed.
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