Rusty Bolt

Still dealing with trying to break the nut free!  I think I'll get a portable torch and apply some heat. Stay tuned.

Exhaust manifold bolt/nut

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.

Priority project-pellet furnace

I'm tired of the high propane prices do I'm installing a pellet furnace. Back in a few days.

Yet more electrical issues, kind of...

It's been almost a month since I posted, but I have been working on this.   But with the serious lack of snow and the holidays, it has't been a priority.

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.