Join Date: Jun 2019
Location: Bealeton, Virginia
Engine Swap update
The removal and the re-installation of the 2000 engine in my 91 GL1500A went pretty smoothly over the long 4th weekend. It took about 25 hours to complete the entire process. I would estimate that 6-8 hours of that time was getting to the engine, reassembly after the swap, and of course a few do overs.
I took the 2000 long block and everything else from the existing 91 engine without modification. It started right up (after I was happy that it had oil pressure) and the carbs were still within tolerance so there was no need to resync them. After the first week back on the road commuting I am getting just over 42mpg, power is much better with the 2000, and its nice to be able to roll through the gears smoothly again so I am pretty happy with it.
All in all not a bad experience. I appreciated all of the advice I received while I was researching the project, especially replacing everything rubber and all of the maintenance items while the motor was out and reading and following the 34 steps in the book.
Looking forward to another 200,000+ miles on the ole steed!