The engine and the bike met today. I also took an angle grinder to the frame, so I may be past the point of no return on this project.

To put the engine in the frame, the rear brake master cylinder mount and to top Heim joint mount had to be removed. With those items removed, the engine slid into the bay, but it isn't in the right place yet. As you can see from the photo, the engine is too tall. I've already removed the exhaust manfold and turbo-charger and prepared those items to be mounted low in the front of the engine, but the intake manifold still adds enough height to prevent the engine from sitting straight in the frame. The current best solution for this is to cut and plug the intake flange. The intake air would get to the engine by remove one of the plugs from the end of the intake manifold and installing a flange there. In the photo above, the plug is the little round item directly above the center of the flywheel. There is a second plug on the other end of the manifold, allowing a choice for the intake from the turbo.

The second problem with the engine is that it's still too wide. In the lower left of this photo, you can just see the end of the input shaft for the transmission. The flywheel is too far to the left for an attached pulley to drive the transmission. This means the engine will have to be moved left (or the transmission shaft lengthened.) Moving the engine will also cause the bike to be heavier on the right side. Perhaps it's time to look into the choices on primary belt conversions and determine the actual location of the transmission pulley.

On Monday, I'll show it to Kevin O'Grince. He's the owner of Artisan Auto Body in Manassas Park, VA. I'm doing the work at his shop. He may have additional ideas.

Some additional clearance might also be gained by sectioning the oil pan. With the engine moving to the right, it may only be necessary to cut the right side so the engine doesn't interfere with the frame rail. The rail would need to be replaced with a brace to maintain frame strengh, but that might also be a method for including a skid plate for the oil pan. There are a lot of options, none of them easy, but all are well within the capabilities of the guys at the shop.