1. Guest,
    We need good tech writers that are willing to help out here at ZL-OA. If you like taking photos of jobs as you perform the steps on your repairs, have historical ads/documents from old magazines, or any else you think belongs in the Technical Library than you might be able to help. Send a private message to Furchin, Mudrunner88, Chris, Jarney, Wuputt, or Markus56 and we can lead you in the right direction to get started.
    Dismiss Notice

1999 Kawasaki Vulcan Drifter Engine Swap.

R. J. Feb 27, 2018

  1. R. J.

    R. J. Senior Member

    7,644
    268
    128
    :hello: My Neighbor Mike B. & I are doing a motor swap on his 99 Drifter. Yesterday we got the old motor out. We started at 1o AM & stopped at 6 PM with many breaks in between. :laughing7:. The old motor has 58 K miles on it. Mike has replaced the bevel bearing 3 times so something else in side must be bad. The replacement motor has 18 K miles on it. $1600 shipped. Today we are installing the new motor & will start putting the rest of the bike back together. IMG_5393.JPG IMG_5394.JPG IMG_5395.JPG IMG_5396.JPG
     
    Last edited: Feb 27, 2018
    markus56 likes this.
  2. 87kawzl

    87kawzl Senior Member

    1,319
    77
    143
    I like the looks of the drifters. lifted the style right off the old indians.
     
  3. R. J.

    R. J. Senior Member

    7,644
    268
    128
    IMG_5397.JPG IMG_5398.JPG IMG_5400.JPG IMG_5401.JPG :hello: Mike has Indian air brushed on the fuel tank. :laughing7:. We got the motor in by 12:30 PM. We rode to our local parts dealer to get a new oil filter for the Drifter. Then we went for a ride to get lunch. I rode my Sisters Suzuki 650 & Mike rode my ZL 10.
     
    markus56 likes this.
  4. R. J.

    R. J. Senior Member

    7,644
    268
    128
    :hello: After we came back from lunch & a 2 hour ride we put on hoses, vacuum lines & pluged some connectors together along with dielectric grease. Mounted the left running board, air box rear panel. Lubed & routed the throttle cables the correct way. Re-wrapped some of the wiring harness loom. Also we cleaned all the silver & black paint from the frame that the PO did. Flushed the radiator & coolant tank. Installed the new oil filter along with 4 quarts of 20/50 V twin Amsoil. We spent about 4 hours on the bike today. We are going to use Engine ice for coolant. We used my mini transmission jack during removal & installing of the motor. It made things so much easier. Tomorrow we will try to finish up but I won't count on it. :laughing7:. IMG_5402.JPG IMG_5403.JPG IMG_5404.JPG IMG_5405.JPG IMG_5406.JPG IMG_5407.JPG IMG_5408.JPG IMG_5409.JPG IMG_5410.JPG IMG_5411.JPG IMG_5412.JPG IMG_5413.JPG IMG_5414.JPG
     
    Last edited: Feb 27, 2018
    markus56 likes this.
  5. furchin

    furchin ZL-OA Co-owner Staff Member Administrator Super Moderator Supporting Member

    2,050
    36
    143
    If you really would have helped him instead of standing there taking pictures the job may have been completed by now.:evil::evil:
     
    kawboy and R. J. like this.
  6. R. J.

    R. J. Senior Member

    7,644
    268
    128
    :Laughing4:. :hello: Mike shot 3 times the pics that I did & about a 1/2 hour of video so that we would know how to put things back together correctly. Almost every time we went to use the pics they didn't help. :laughing7:.
     
  7. R. J.

    R. J. Senior Member

    7,644
    268
    128
    :hello: Yesterday we worked on the Drifter for 4 hours. Then we went on another bike ride to the Kawasaki Dealer in Sanford FL to get plugs, brake pads & such. Next we stopped for lunch at the Fox Head in Osteen & that blew the rest of our day. :laughing7:. Today we started at 1 PM & finished up around 6 PM. Mike's dog Balla was Supervisor. :). I'd say that it took us 20 hours to do this engine swap & 20 hours screwing around. :laughing7:. IMG_5415.JPG IMG_5416.JPG IMG_5417.JPG IMG_5418.JPG IMG_5419.JPG IMG_5420.JPG IMG_5429.JPG IMG_5430.JPG IMG_5432.JPG IMG_5434.JPG IMG_5435.JPG IMG_5436.JPG IMG_5437.JPG IMG_5424.JPG IMG_5423.JPG
     
    Last edited: Mar 1, 2018
  8. 87kawzl

    87kawzl Senior Member

    1,319
    77
    143
    Sounds like 40 hrs well spent. Looks like a sweetheart supervisor.
     
    R. J. likes this.
  9. R. J.

    R. J. Senior Member

    7,644
    268
    128
    :hello: Yes it was. :notworthy:. Also Mike treated me to lunch the 4 days that we was wrenching on his bike. :notworthy:. It was really hot out to. We had 24 days of the 28 days of Feb in the mid 80s which is a record for Central FL. I dread this coming Summer.
     
  10. kvalheim

    kvalheim Well-Known Member

    607
    28
    63
    One of our friends just got back from Florida on Monday. He spent two weeks riding his Harley and going to the Daytona race. He said it was in the 80's. We call him the tan man now. Here in WI we have finally had 40's and 50's for the past week. Congrats on a job well done R.J.
     
    R. J. likes this.
  11. markus56

    markus56 ZL-OA Co-owner Staff Member Administrator Super Moderator Supporting Member

    3,165
    123
    158
    Yeah, congrats on the swap R.J. but you never said how's it running?
     
    R. J. likes this.
  12. kvalheim

    kvalheim Well-Known Member

    607
    28
    63
    :Laughing4:
     
  13. R. J.

    R. J. Senior Member

    7,644
    268
    128
    :hello: The Drifter runs great for a toad. :laughing7:. I noticed that the motor tics but Mike said that it's the nature of the Drifters. The ticking goes away after it gets up to temp.
     
  14. Harriminator

    Harriminator Senior Member

    721
    112
    138
    Low enuff for ya to reach earth or w/ the 'special' boots only...?:laughing7:
     
  15. R. J.

    R. J. Senior Member

    7,644
    268
    128
    :hello: I'm tippy toe on the Drifter. :laughing7:. Also I burned my leg on the exhaust pipe. :laughing7:.
     
  16. R. J.

    R. J. Senior Member

    7,644
    268
    128
    :hello: Guys Mike B. Drifter has developed a FI problem. I pretty much am at a loss on this one so I need help. The bike starts right up & runs for say 10 min. Then the bike bucks 3 or 4 times & dies. Then the FI fuel injection light comes on. Any input is greatlly greatly appreciated.
     
  17. furchin

    furchin ZL-OA Co-owner Staff Member Administrator Super Moderator Supporting Member

    2,050
    36
    143
    Don't really know anything about bikes with FI but with FI you have a fuel pressure regulator or (whatever it's called) that has to maintain a certain psi. I would see if you can find the specs and testing procedures for this unit.
     
  18. R. J.

    R. J. Senior Member

    7,644
    268
    128
    :hello: OK: Thank's. I am looking through the Service Manual. It has 104 pages just on the DFI = duel FI. The fuel pump is in the fuel tank. The DFI relay is down next to the fuse box. We can hear the fuek pump come on when the bike is cold but after warm up we can no longer here it. I'm going to take the fuel pump out to check for broken wires.
     
  19. R. J.

    R. J. Senior Member

    7,644
    268
    128
    :hello: While we pulled the fuel tank back off. Checked all the connectors used in the DFI circuit. After reading through 104 pages on the DFI we done the self test. You need to disconnect the CDI/ECU & jumper one wire from the plug to the CDI. Then turn the key off & on twice. Then on the instrument panel the DFI light flashes like morse code. We got no codes. So we put everything back together. Mike & I went for an hour ride & the Drifter ran fine. Mike said that the bike runs better than it did with the old motor.
     
  20. 87kawzl

    87kawzl Senior Member

    1,319
    77
    143
    Glad it's running good for him
     

Share This Page