2015 and still working on this. Gave up and cut the nut off, then picked up a new one at the hardware store. Temp has been around 0, so I'm waiting for Temps in the double digits before working on this again.
Wednesday, December 31, 2014
Tuesday, December 30, 2014
Finished with the electrical, other than the TSS switch, I'm leaving that disconnected for now. Next step is to bolt up the exhaust. But one of the manifold nuts is rusted to the stud, so I removed the stud and will let it soak in oil for a few days to see if it will loosen up. I'll give the clutch a try next.
Monday, December 29, 2014
Sunday, December 28, 2014
Once I had the motor bolted in and torqued down, I connected the coolant hoses and the electrical. With the electrical hooked up I decided to do a quick pull test to verify my connections. Well, guess what? That's right, no spark! I double-checked the connections, made sure my tether was connected, key on and on/off button up. So, I grabbed my voltmeter and started testing all electronics from the stator up. All components tested fine, now what?!
Quite a long story made short, I found more than a few references to disconnecting the yellow wire harness from the stator and testing for spark then. Supposedly this bypasses ALL handle bar controls. I did this, still no spark. Then I remembered! I had a problem with the TSS (Throttle Safety Switch) and had disconnected it before the original motor went. So, despite what I read about the yellow wire harness bypassing everything on the handle bar, I disconnected the TSS. SPARK!! So much for the internet forums. I am ashamed of how long I went before doing this. That just goes to prove, don't believe everything you read.