82 harley cart with suzuki 440 FC engine

[raydhd]

Had some time this late a.m. Fabbed up the driver's side engine mount so the belt could be installed and checked for fit. Also clamped the muffler on to the header pipe. So things are going more or less to plan. The muffler comes VERY close to the body. Probably will test run the engine with this muffler and see how loud it is and how it runs.

[raydhd]

Disassembled the mikuni carb and checked float operation. Installed it on the engine and test ran using electric fuel pump with gas/oil mix in the tank. I started it with starting fluid.
I ran it briefly with some mild revs to hear how the exhaust sounds. To my great surprise it sounds much like an old two stroke street bike.

[G1-G9]

Looking good Ray.

[raydhd]

Since the exhaust system seems to be quiet enough I bent the old S/G bracket off the Harley as a muffler brace.

[raydhd]

Originally Posted by G1-G9

Looking good Ray.

Thanks, I am slowly working my way thru it leaving pics as I go hoping to help anyone wanting to rescue one of these old 2 stroke Harley/Columbia carts.

[raydhd]

Today I wired in the bosche 5 pin relay to shut the engine down. Terminals 85 and 86 run to the on/off 12 volt switch.Terminals 30 and 87 run to the engine magneto.This net effect is that when the 12 volt power is off it opens the relay and stops the connection from the magneto to the coils shutting the engine off.Also LOOKED at the throttle situation. The harleys throttle cable pushes out where the mikuni carb needs it's slide pulled up.I need some kind of motion reversing linkage that is durable and SAFE! Any ideas would be welcomed.

[raydhd]

I did run the engine several times today and what I have done so far appears to be working. Ordered a 1 3/4" 2 stage dirt bike air cleaner from bike bandit and a bell crank unit from speedway motors. I was thinking on adapting the original harley air cleaner but I wondered if there was anywhere near enough flow capability there.I guess off to Ebay it goes.This thing sounds pretty good. Of course you really can't tell until you get it on the road and floor it. That is still a ways off.

[raydhd]

Mounted and wired the kohler rectifier/regulator today.Also found the belt tension to the cooling fan was way loose. Removed shims from the pulley it looks good now.I also added beefier brackets to the motor mounts.Little by little.A whole lotta man hours on this swap.Makes me appreciate how easy the Vegascarts clone into the G14 was.

[raydhd]

After reading a lot on snowmobile sites I decided not to use the oil injection system so I cut the drive tongue off the oil pump and plugged all the lines.I really can't get over how good this thing sounds.That was one of my big concerns to start with. Maybe tomorrow if I don't get diverted elsewhere I will get the starter wiring worked out. Up till now I have been pull starting it.

[G1-G9]

Looks like you have a little busy.