86 aspy SEi engine replacement.

[stuartb306]

Good morning ladies and gentlemen. Its been quite some time since i was last in here. You might remember me by my old user name, roadwanderer2. Lots of things have been going on with me over the last few years. I've moved from Tennessee to Arizona and i love it here. Ok, i'll tell more about it later, right now my problem is im swapping out the motor on my 86 aspy SEi, and i can not for the life of me find the male connector plug for the pulse generator. its been about 2 months since i removed the motor while I've been waiting for the new-ish one to arrive and i'm reconnecting everything out of memory, Yeah, i know, memory is going LOL, anyway, can someone PLEASE help me locate the other connector plug?

Thanks in advance, and its great to be back on this site again. (Hello's to Wingadmin and everyone else).

Stuart.

[stuartb306]

Ok, i have another electrical question. I have 3 wires that supposedly have to be connected to the Neg. side of the battery. In the photos i took, i have the 3 wires in my hand and going from left to right, the wire with the red color on the end of it comes off the starter, the wire with the brass end is connected to the frame, and the last wire on the right comes down from between the frame. When i put the brass ground wire on the Neg battery post, it gets very hot very fast. I'm not sure if i have them correctly connected to the battery, but when i press the starter button, all i get is the starter solenoid click and a "humming" sound coming from somewhere on the engine when i press the starter button and stops when i release the button. Also, one more question.......there are 2 wires that go to the electric fuel pump, a brown and a green. I had them marked to know which wire went where, but the marking wore off and im not sure which is for the + or - posts on the fuel pump.

STILL haven't found the PG connector plug

Can someone help me with this also?

Stuart.

[Rednaxs60]

Good afternoon Stuart - I remember you.

The three wires you have in your hand - second post. The one from the starter goes to the "M" side of the starter solenoid. The positive cable from the battery should go to the "B" post on the starter solenoid. The one from the frame, should be connected to the engine rear upper mount and goes to the negative side of the battery, and the third will have to be searched - need more information.

You mention the PG connector. Do you mean the Gr/Gl sensors on the back of the right cylinder head, or the Ns sensor that is in the timing belt area?

There are 4 coloured connectors beside the PB sensors. The Gr/Gl sensor connector is White, the Tw sensor coupler is Blue. The Ns sensor is a 2 pin connector that is in the connector bracket that is part of the coil bracket.

The fuel pump wires: green is ground, brown is positive. If you have an original pump there should be a brown wire on the fuel pump. To test the pump, disconnect the outlet hose and connect a 12 VDC source up to the pump and see which is which. It will put out a lot of fuel if you get it right.

Good luck.

[stuartb306]

HEYYYYYYYYYYY REDNAXS ! ! !. How are ya buddy, ltns. Glad to see that your still "among us" lol. THANK YOU THANK YOU THANK YOU for all this wiring info. YOU ARE A GODSEND . I suppose i have the original fuel pump on it with the 1 grn and the 1brn wire, I DID have them marked on the pump,(color coded), and i guess with moving everything around down there the ink discapeerded lol. That might be the problem with the 3 battery wires.......TO MANY WIRES . I just finished for the day and i'll pick up where i left off in the morning. I'll keep my progress posted. Oh, im also replacing all the brake pads, F & R tires. I can't wait to finish this so i can get back on the road.

This is a pic of the bike before i loaded it into the back of my p/u and drove from TN to AZ. I had a "slight" accident with it back in Aug, hence the need to replace the motor.

Take care my friend,

Stuart.

[stuartb306]

Good (way to early) morning one and all. This is a stock photo of the PG and the connector that i can't find the female side to plug it into.

. If someone knows where its located i'd be very grateful.

Stuart.

[stuartb306]

Hey Ernest, you were 100% right about the 3 wires, and i found out what the "mystery wire" was. The original starter cable was already connected to the solenoid and i was trying to add another one to it , so i removed the starter cable that was still attached to the starter and put the one that is from the solenoid on it.

Here is a pic of the PG connector. It has a clear connector and 4 wires going into it. 1 blue, 1 white, one green, and one yellow. STILL haven't found the other half of it.

Other than that, now i can start putting the exhaust system back on, well, at least the header pipes so it has some compression to maybe try starting it up. Before i install the back end of the bike, im gonna remove, clean and replace the rear brake pads, and since im a retired S.E.A. mechanic, it'll be just like working on a small car.

Stuart.

[Rednaxs60]

The Gr/Gl sensors are a white 4 pin connector. This is also in the connector bracket that is part of the coil bracket, right beside the Ns sensor two pin connector.

[stuartb306]

Earnest, thats great to know, but, there is an old saying, "a picture is worth a thousand words", and "location location location" LOL. Is there any way you can take a pic of its location?. Most of the connectors under and inside of the fairing don't have brackets, they are just laying there. As your sitting on the bike, is it on the right side, or the left side up under the fairing.

Stuart.

[Rednaxs60]

Earnest, thats great to know, but, there is an old saying, "a picture is worth a thousand words", and "location location location" LOL. Is there any way you can take a pic of its location?. Most of the connectors under and inside of the fairing don't have brackets, they are just laying there. As your sitting on the bike, is it on the right side, or the left side up under the fairing.

Stuart.

On the left side under the handle bars. See pic for location:

[stuartb306]

Man, they really have that connector tucked in there huh. No wonder i can't find it lol. Let me go outside and see if i can find it.

Thanks Ernest,

Stuart.

[stuartb306]

I wish MY electric connectors looked as neat as yours are. As you can see by the pic, mine are just laying in there. In the pic, you'll see the bracket where the connector SHOULD be, but i'll be darned if it isn't there. and the right side wiring looks just as jumbled up as the left side does. I'll tell ya, im 'bout ready to pull the entire faring off to find this connector.

Stuart.

[stuartb306]

EURIKA, I FOUND IT!!!! lol. You'll never guess where it was. It was tucked up under the lower triple tree. Thats why i couldn't see it. Connected it, turned the key on, pressed the starter button and it started on the first shot. Bike sounds NASY with just the header pipes on lol. I'm gonna check into changing the mufflers to give it a little more "Throaty" sound, nothing to "annoying" or "obnoxiously" loud, just enough to let someone know im there . Next is installing the radiator and rebuilding both front brakes. Still waiting for my new tires to arrive so i can take them to the bike shop to have them mounted and balanced.

Stuart.

[Rednaxs60]

When I have to do a lot of work in the front, it's advantageous to remove the front fairing. Lots of room to work when it is off.

[stuartb306]

Do you remove it by yourself or do you have someone to help you remove it.

Stuart.

[Rednaxs60]

Both. Easier with help.

[stuartb306]

Yeah, these wing fairings are heavy. I tried to remove mine by myself and didn't quite make it LOL.

Here's a pic of the motor back onto the frame. It's all wired in and running again. I'm now trying to figure out how and where to hang my new Harley mufflers.

I hope they sound as good as they look.

Stuart.

[stuartb306]

Well people, its been a long battle putting my aspy back into shape. I did a LOT of work to it in the last couple of months and here's what i have.

what i removed, repaired and replaced are:
1- both f and r tires.
2- new fork seals, dust boots and fluid.
3- reconditioned all 3 calipers.
4- replaced all brake pads.
5- added new rear tail/stop lights and trunk bumper lights and rewired the "Aspencade" reflector stop light bulb to light up when i put the brakes on. It was a "safety" issue to be seen better as was the new added saddle bag stop lights, I hope.
6- new-to-me engine from an 85 LTD.
7- removed and replace all bad wiring front to back
8- new front wheel bearings and seals.
9- new battery, (replaced under warrantee)
10-removed bad clutch slave cylinder and replaced
it with the one from my old motor. (Rebuilt it a couple of years ago).
11- put on the Harley mufflers and took them off again to reinstall my OEM mufflers because it made the bike TOO loud when i cracked the throttle. Anyone wanna buy a set of Harley mufflers? lol.
12- went thru 2 bottles of brake fluid to bleed everything out. it was all "air bound".
13- reinstalled my electric windshield wiper for the Monsoon Season we have here in Arizona.

Below are a few pics of my work. The last photo is what my wing looked like when i had my "accident" 2 months ago.

Now, i have a problem, the rear tire is rubbing against the right side swingarm. Last pic is what the spacers look like on the axle. Do i have them in the right order between the caliper and the hub? Do i have the wide spacer facing the wrong way? If someone can help me this i would greatly appreciate it.

[stuartb306]

Now that all the major work is finished, time for a "body make-over". I decided to repaint her but not in the original factory colors. She needed a more "modern" look to her, so i went with a Sublime Green with black inserts and pin stripes. I'll post a few pics of what she looked like and what she looks like now. I added new rear tail/stop lights on the rear saddlebags along with an upper trunk lid wing with red LED lights in it, and a front lower air dam with amber marker lights. Let me know what ya'll think.

Thanks,

Stuart.

[Rednaxs60]

Looking good, enjoy!

[stuartb306]

Hey there Ernest. Thanks for the compliment. Somehow i thought you would be the first to comment on it lol. Yeah, she looks a little more "up-to-date" with the new colors. Hope everything is going well for you and all of YOUR "projects" as well.

Stuart.

[WingAdmin]

I like the green and black! People might mistake it for a Kawasaki, however.

[stuartb306]

LOL, thanks Scott. I think after im finished putting all the "Honda" badges back on, i think ppl will notice its NOT a KZ, and if they do, well, let their eyes keep deceiving them .

Stuart.

[Rednaxs60]

I agree with Scott, that colour green is Kawasakiish. Need more black pinstripng on the rear bags, shelter and side panels to tone down the green and really make it "pop".

[stuartb306]

Hey Ernest, not to worry, im far from done with the pin stripping. Trunk, saddlebags, front fender, tank shelter, they all need to be stripped and badges put back on. These pics are what the bike looks like in its "almost completed" stage. Don't get me wrong, the original colors were nice, but it "time perioded" and needed a "face lift" if you know what i mean. Consider it a "Resto-mod", and with all the new parts and rebuilding, it runs and rides great.

Since I'll FINALLY be having my wrist surgery on the 7th of next month, I'll be off the bike for at LEAST 5 months, so I'll have plenty of time to finish up the "small stuff" lol. Driving my cage is gonna be hard enough, I have NO intentions of trying to ride with a cast on my right arm.

Stuart.

[WingAdmin]

Aw that's terrible news Stuart! Here's hope you heal back to normal soon. I will advise you: once the cast comes off, do the PT!!! It's hard, it hurts, you won't want to, but from personal experience, it is better than having the long term pain and dysfunction if you don't do it.