Engine Removal

[beechfront]

I haven't had a chance to look at the manual yet, but I'm getting ready to remove the engine for painting. I was wondering what has worked good for people. I assume this will not be something I can do on my own. How much does that sucker weigh? I'm planning on getting a friend to help me lift that thing out of there and set it down on some cardboard.

any thoughts?

[xssiveone]

I think this is best done with a helper, altho Gary (Sistysix) did it by wrapping a laying the bike on it's side and wrapping a strap around the engine and lifting it out with an overhead winch.

When I did it, I positioned a platform on the right side of the bike and slid the engine onto it. I also removed carbs and middle gear box first to eliminate some weight.

When I put it back in, I used 3 people. I set the engine on it's side, and then lowered the frame onto it. I first wrapped the frame in rags, but still scratched it a bit.

[beechfront]

I would prefer to do it on my own, that way I can do it when I have time and won't have to inconvenience anyone. I'll probably try rigging something up with the rafters.

[sixtysix]

read this thread, has my pictures in it.

http://www.xs11.com/forum/showthread...&threadid=1647

[Garry W.]

I've had my engine out 3 times mainly because I screwed up when I fixed my second gear and forgot to put a detent pin in the shifter when I put the engine back together.
But really taking the engine out of the frame isn't to bad it takes at least two guys three is better. Just make sure you have everything disconnected. Something as simple as the horn brackets can cause you grief if you don't take them off. Have fun!!:

[uk1.1s]

Engine out pit-team

Looks like you are not on your own Garry W ...

I've had my engine out 3 times mainly because I screwed up

A man after my own heart - think I'm upto four times now for similar reasons (the first two being within 32 miles - after bad diagnosis)

My method is to put a small scissor jack under the engine for support and place a wooden pallet beside the RHS of the bike to slide the engine onto. The pallet is one of my Very Useful Things in the garage as it's not a full size pallet like those trucks use but about 1/2 size and fits easily in my narrow garage without taking up all the floor space. As the engine bolts are undone I lightly jack the engine up (not too much of course) to support it. The engine can be wrestled free by a strong enough / fit person - but beware of dodgey backs and those unused muscles. Obviously you have to remove carbs / exhaust and unbolt the shaft under the rubber boot. I have also found it useful to move the coils out of the way and have even taken the cam-cover off to afford a tiny bit of extra room.

Garry's right too - the horn bracket needs removing to avoid trying to do it whilst supporting an unbolted engine in the frame.

ONce on the pallet I have normally got a mate and even strong girlfriend to help lift the motor up onto the bench. Removal of things like the middle gear / head and cams, clutch, generator helps the lifting process no end. Otherwise, find something comfortable on the floor to sit on and work off whatever support / pallet you have handy

[wpc57]

Only if your girlfriend is an East German weight lifter...

Mine is out as we speak and I think the platform with a jack under the motor and AT LEAST 2 GUYS. The MOTOR is HEAVEY!

[beechfront]

those of you that have had the engines out - what do you think it weighs? i'm guessing 250.

[Bill__Woods]

Hello,
We just put R&R an engine in an 82 Xj1100. We used a 3 1/2 ton floorjack with wood block on the rear axle nut. picked the bike up and set the front wheel into a round plastic trash can about 2.5 feet high. We had a few jackstands coated with shoprags that we moved several times during the process. we had the whole bike off the ground and rolled the engine (small 4 wheel dolly - Harbor Freight Tools) under it into position. Then we carefulley lowered the bike down around the engine. I pulled the engine and my friend picked the bike back onto the wheels. Engine in chassis, just use small floorjack & a few prybars to align.
I have done 3 -4 big bike engines in the past, and this is the easiest way yet (without a hoist).

I hope this helps someone