The engine removed from the frame.
The stator is under the round cover with the access plug in the center
in the upper middle of the engine (straight up from the
Below it and to the right is the clutch housing - I'll be inspecting
the clutch plates and springs while I have the covers off.
A closer view of the engine sitting on
the bike lift.
This will be a good time to replace the thermostat and inspect the
I left the carbs in the frame so I didn't have to mess with the
Gotta love bungee cords!
Here's the empty frame from the right side showing the left lower rail
Here's a look from over the trunk looking forward.
I put the left frame rail back in place for this shot.
This is as far as I've progressed today.
I'm not going to remove the rear engine cover until the replacement
parts arrive but I'll add more photos as I complete the job.
The parts are all
here, the weather is fair, and Maria has time to help me, so here we go!
Taking things apart. The pulse generators and advance
mechanism are off, and the clutch cover is next.
A couple more bolts and the clutch cover is free.
The clutch cover is off. Now she knows why I put the catch
Maria has the rear cover off, with a little help from a block of wood
and Mr. Hammer.
The stator is barely visible in the rear cover just to the right of her
Here's the back of the engine.
The alternator rotor is on the top left, the little shaft to
right drives the pulse generators, the larger shaft with the spring is
the output shaft that connects to the driveshaft, and the clutch is the
large round assembly in the lower center.
Here's the old stator after removing it from the rear cover.
The burnt winding is visible at about 4 o'clock.
Rear cover with the new stator installed. We used red
Loctite® and a tap on the impact driver to secure the screws.
Here's the rear cover ready to go back on with the new stator and new
output shaft seal installed.
The rear cover is on. The clutch cover is next.
The clutch cover is on, and we are ready to set the initial clutch
Much easier here than under the bike!
Maria is happy to see the engine back together and is anxious to see it
back in the frame!
This is the stopping point for today.
The next step is to move the rest of the bike out and lift the engine
back into place.
August 4, 2005
With cooler weather back for a few days, it was time to get to work.
The starting point.
After about an hour of work, the engine is back in place and we're
starting to fasten things down.
We lost our shade so we moved back into the carport.
Here the carbs and intakes are in place.
The yellow wires above the carbs go to the regulator-rectifier.
We are going to direct wire them to the stator pigtail (by the
battery), bypassing both OE connectors.
Here on the right side you can see the manual fan switch and wiring.
We parallelled the manual switch across the thermoswitch and wired the
SPDT (center off) manual switch so that either ON would energize the
You can also see the remains of the right fairing lower - what's left
of the part that came off outside Oklahoma City on the trip home from
Getting to the end of the job. The radiator, cooling fan, and air
box are all in place.
Here's where we are stopping for today.
We still have to finish the stator wiring, install the exhaust, fill
the cooling system and crankcase, and install all the bodywork.
August 5, 2005
Today we got a late start on things but it went well. So well, in
fact, I forgot to take pictures until after we had a lot done.
The exhaust is on, the stator wiring is done, the cooling system and
crankcase are filled, the engine has been run and now we're putting on
the tank shelter.
At the same point as the previous photo, from the other side.
The tank shelter is done, the seat is installed, getting ready to
install the left lower fairing.
Of course, I can't put the right lower fairing on - it disappeared
outside Oklahoma City!
The engine guards are on and tightened down - it's checkride time!
Getting ready to roll it off the center stand and take a test ride!
For old times' sake...
Hey Roundman! Does this look familiar?
I took the bike for a short ride, then Maria and Kristine took off for
a longer ride.
I tried to get a photo of Maria's smiling face but the light was lousy
and the photo didn't turn out.
We had to swap the battery out of my Wing into Maria's bike - her
battery ended up being weak after all.
I'm reading 14.2 VDC at the battery now, the turn signals still work at
idle and everything seems to be working well.
© 2005 John Amdor III