The Aspy Project

[ritalz]

Will all the plastic and engine guards still fit? Lookin good.

[Track T 2411]

Everything fits except the lower fairing, which can be carefully heated and bulged out on the very bottom. I haven't done that yet. I'm also not sure if the bottom cross-over trim fits or needs to be modified. That's been the least of my worries, lol.

[CYBORG]

When I did mine the only thing that needed modification was the crossover piece At the lower radiator position because the bottom of the radiator was kicked out a bit. minor modification.

[Track T 2411]

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Finished cleaning up the wiring...

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On the left is the red power distribution block. The alternator feeds this, and ties into the original red/ white charging wires. Just below it is a 60 amp relay switched by the ignition that feeds the auxiliary fuse block on the right. Right now it has three circuits, the alternator lead and sense/ excitation wire, a clean feed to the coils, and the new fan, which also has a relay in the circuit, switched by the original fan power circuit.

I plan to add a circuit for a louder horn (with relay), and two phone charging ports, one with a built-in voltmeter. At some point in the future I'll feed another fuse block at the rear of the bike for trailer lights...

[Track T 2411]

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Almost there! Waiting on a lower radiator hose that's 'supposed' to have a portion that will allow me to skip using a spacer.

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[CYBORG]

{'d like to see that hose and a part number when you get it. The one I'm using is a bit of a stretch

[Track T 2411]

I'll certainly let you know!

[CYBORG]

Thanks

[Rednaxs60]

I have used the Morosso spacer kit 63610. Works well.

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water pump spacer kit install.jpg

[CYBORG]

I like that. Many thanks

[Track T 2411]

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Yikes! A $22 coolant hose for four inches, and no clear 'cut' idea of which portion to use! I had to give it a little persuasion for the last 1/4 inch or so, so it's under a bit of tension. The top end was the start of a bend, and the inner dimension is a bit too large, but it seems good. I guess we'll find out soon!
The hose is a Gates 21008, I ordered it through O'Reilly's.

[Rednaxs60]

Good fit. Nothing inexpensive when its comes to these older GWs

[Track T 2411]

Well, she's up and running! The first test run went well, except for the fact that I overfilled the coolant, so it was kind of difficult checking for leaks. The alternator is charging as it should, 12.9v at idle, 13.8v+ above 1500 RPM. The fan switches on a it should.
After cleaning up the coolant mess and screwing around with the plastics (I'm not very happy with the results), I ran it again, and quickly discovered a split fuel line. Shut it down and called it a day...

[Track T 2411]

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Well, the fuel lines were replaced at some point, but they're hard as a rock, and the fuel filter looks older than the bike, lol! Time for a trip to the auto parts store!

[ritalz]

Kind of surprised you didn't see this before now. What was the problem with the plastics?