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1999 Kawasaki Vulcan Drifter Engine Swap.

R. J. Feb 27, 2018

  1. R. J.

    R. J. Senior Member

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    :hello: Mike's Wife Mary is happier than he his. She told us if the bike wasn't running by Bike Week Daytona she was going to put her foot in our A holes. :laughing7:
     
  2. R. J.

    R. J. Senior Member

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    :hello: The Drifter developed another elecrical problem Sat. afternoon. We spent 12 hours Sun & 4 hours today debugging/trouble-shooting the electrical/electronics. It kept blowing the 15 amp DFI fuse. We found that the wires that go from the DFI fuel pump switch to the fuel pump was shorted to chassie ground. We fixed that but still had another issue. Trouble-shooting lead to the finding of the throttle positioning sensor on the fuel injector was cracked & pulled away slightlly. So we seated it back in place & epoxed it. You can't buy one because it is part of the throttle body. First we ran the self test diagnostics & never got any fault codes. Before we did all this we replaced the DFI switch itself last week thinking it was bad. The part was $30 + one day shipping from partzilla was $10. We are going for a test ride but first the battery needs charged. We're hoping for the best. IMG_5542.JPG IMG_5544.JPG IMG_5543.JPG IMG_5537.JPG IMG_5538.JPG IMG_5539.JPG
     
    Last edited: Mar 12, 2018
  3. R. J.

    R. J. Senior Member

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    :hello: When Mike & I was trouble-shooting the wiring harness loom first we did some researching on the Drifter, Mean Streak & Nomad Fourm's. All 3 models have basically the same wiring harness. I'd say that at least 40 other people has had a similar problem but none has ever said how they went about fixing the problem. People just give up to easily. While Mike went on the Drifter Forum & told them how we went about it.
     
  4. R. J.

    R. J. Senior Member

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    :hello: Mike's Driffter continues to plague us with DFI = (Digital Fuel Injection) problems. It ran fine for the most part. At times it would hip cup then come back. A few days ago it took a crap. :laughing7:. It no longer blows the 15 AMP DFI fuse. We did replace the DFI relay awhile back. ($38 shipped) 1 day. So back to the drawing board we went. We dug into the wiring harness loom again checking for floating GNSs/RTNs/COMMONs. We found none. Every (RTN/COMMON/GND) wire read 0.008 OHMS. Just for safety measures we added GNDS to the frame from the ECU/CDI just as SHOULDABEEN ENG said to do on the connie forum. We also done one from the fuse box. Next we tested all the components for the DFI for 5 VDC & 5 K ohms. All checked out good. Yesterday Mike bought a fuel pressure gauge test kit. Yesterday we installed the new fuel filter $52 shipped in one day that came from Partzilla. The old one had a bunch of black junk in it. When I blew in it air did not flow freely/correctly. We installed the new OEM fuel filter. Next we hooked up the fuel pressure gauge as per the Service Manual. Test went as follows. 1. Key off 0 psi. 2. Key to on 36 psi. 3. Bike at high idle 38 psi. 4. Idle down. 35 psi. 5. Full throttle. 40 psi. 6. key to off. 34 psi. All in spec. So I called my friend Don in PA who is the Service Manager/Lead Tech for Tom Cycles in Indiana PA Honda, Kaw, Suz, Yam Dealer. He said test ride the bike for an hour or so & check readings again per manual. Also check reading at different speeds. At 6 miles into the test ride at full throttle pressure was 40 psi then started bouncing between 30 to 35 psi. Then dropped to 25 psi, hip cupped a few times then dropped to 10 psi then in a few seconds came back to 40 psi. It did this 3 more times. At one point it just shut down. Called Don again. He said either one or both the DFI fuel regulator ($90) & fuel pump ($392) is going bad. So Mike ordered both. partzilla has to order them. We should get them in about a week. Bottom line DFI SUCKS ASS. :laughing7:.:pain10:.:banghead:.:argue:.:angryfire:.:angry:. I'll stay with 4 carbs. :laughing7:. IMG_5893.JPG IMG_5888.JPG IMG_5889.JPG IMG_5890.JPG IMG_5892.JPG IMG_5894.JPG IMG_5895.JPG IMG_5896.JPG IMG_5897.JPG IMG_5898.JPG
     
  5. Harriminator

    Harriminator Senior Member

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    What's the price for a used Drifter? I mean for parts and so...:laughing7: tmp_9978-s205-1821325844.gif
     
  6. R. J.

    R. J. Senior Member

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    :hello: He paid $1500 for his 99 Drifter 4 yeasrs ago & he has $1200 in the custom paint & air brush work.
     
  7. R. J.

    R. J. Senior Member

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    :hello: The parts came from patzilla for the Drifter Sat. Getting the old fuel regulator off was a SOB. We couldn't get to the rear screw so we had to chisele it out. The old fuel pump had a bunch of sandy mud around it's filter so we drained the tank & used paper towels to soak up the remaining fuel then vacuumed out the tank. Also blew high pressure air in the tank to get any remaining sand out. IMG_5971.JPG IMG_5972.JPG Time spent getting to & removing injector/fuel regulator block 2 hours. IMG_5981.JPG Old/new fuel regulator. New one is slightly different. IMG_5982.JPG Fuel injectors mount to the same block as the fuel regulator. IMG_5983.JPG New fuel regulator $86. IMG_5976.JPG IMG_5977.JPG IMG_5978.JPG Sand from inside fuel tank. IMG_5979.JPG IMG_5974.JPG Old & new fuel pump. New $292. IMG_5975.JPG New fuel filter $44. We are going to use hex head screws/bolts instead of phillips. A while back we also installed a new DFI switch. $38. Total for parts $460.
     
    Last edited: Apr 3, 2018
    markus56 likes this.
  8. 87kawzl

    87kawzl Senior Member

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    Nasty.
     
  9. R. J.

    R. J. Senior Member

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    :hello: I've never seen anything like it. Muddy sand up all around the small fuel filter that is part of the fuel pump. We must of removed 4 oz of sand from the tank with the shop vac. We just came back from a 30 mile ride. No spitting & spudering. The drifter never shut down so hopefully it is ok now. Parts cost $560 not 460. IMG_5988.JPG
     
    Last edited: Apr 3, 2018
    markus56 likes this.
  10. R. J.

    R. J. Senior Member

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    :hello: Mikes Drifter for the past 6 Months has run flawlessly. He's put 2678 miles on it since being fixed.
     

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