Reinstalling an Engine

[geneborg]

I am about to install a '79 XS1100 engine into a '81 XS1100 frame. The '81 got flooded and the engine was frozen. I removed the engine by laying the bike on its side and then lifting the bike off the engine after unbolting everything. This was done by myself.
I am looking for some ideas on a good way to install the '79, preferably alone. Is there a better way to do so other than again doing it in reverse of how I removed the original engine.
I had this engine from another bike purchase where I got a spare engine. I am in process of taking a bunch of parts and "seeing" if I can put together a running bike. As if I don't have enough projects with two other 1100s that are in process of getting "better".
All creative ideas much appreciated.

[bikerphil]

There are a couple of different ideas in this thread...

http://www.xs11.com/forum/showthread...highlight=pipe

[TADracer]

Do it with help.

Since it is alot easier to install with head and cylinders off I would do that. Without the head and cylinders the motor probably still weighs nearly 200 # so I would enlist the help of a buddy. It only takes about five minutes for two guys to position the motor in the frame and slide the through bolts in. That way you do not have to worry too much about damaging paint or bending studs, etc.

[trbig]

The motor is going to be fairly heavy no matter what's on it. It will go with the head on, but is much easier to do if it's off. If it ISN'T off yet and you have no need to do so other than for engine installation.. I wouldn't do it, and taking cylinders off and scraping/replacing a base gasket can be a NIGHTMARE and I would only personally do if I had to. There's also a chance of breaking rings on re-install of the cylinders. Taking off the valve cover will give you a bit more room though. You will also need the oil filter and that cup off of the bottom.

I have no clue how strong you are.. but what I normally do is set the motor into the frame sideways, tail first from the right side. Get a floor jack and put a flat piece of wood on it, then jack up under the middle somewhere. You'll need to rock it a bit back and forth to clear things, but you need to have it only high enough to JUST clear the mounts as you spin it to it's correct position. Keep an eye on the rubber boot on your shaft drive and don't let the u-joint catch it and tear it.

It's a bit of a PITA to get it in there and set right no matter what/how you do it.. but I have done it alone several times. If you have a friend.. even one to help guide it around a bit and see things from the other side.. no heavy lifting required.. it helps considerably.


Tod

[randy]

The lay-down method worked for me. Only have to get a couple of bolts in, then flip the bike up and complete the install. I was able to do it with minimal damage to the new finishes by wrapping the frame rails with cardboard.

[fredintoon]

Fighting gravity

Hi Gene,
I reckon gravity works much better these days than it did when I was young.
Time was I'd grab an engine and up it would come. These days I grab and gravity keeps it held right down.
That's why I got a shop crane. And so should you. Or any other kind of lifting device to haul the lump up against that improved modern gravity while you and your buddy shove the bolts in.

[kjohnson]

When I first tried putting the engine back in my 1100, i didn't have a lot of time and it didn't want to get off the floor, or go in the frame for that matter. The next day I came home from work fuming, grabbed the lump and it was in the frame in a matter of minutes. I wish I knew what I did.

[motoman]

Installing engine

Install from right side. Very easy with 5-min. help from a friend. We set engine on one of those roll-around mechanic seats beside the bike, picked it up and put it in the frame. When almost all the way across I held u-jount flange straight and when moter was in place, flanges poped right into place. Use a punch or large phillips screw-driver to put in one side of mount bolt holes and pry up a bit and run all moter mount bolts in place. Very easy to do. ust don't over think it all.

[fredintoon]

"I got the red mist again - - -"

The next day I came home from work fuming, grabbed the lump and it was in the frame in a matter of minutes. I wish I knew what I did.

Hi KJ,
hysterical strength, running amok, going berserk, there's lots of names for the phenomenon.
It's said that one's muscles are strong enough to break one's bones but one's brain has a limitation circuit. Except the circuit can be over-ridden in times of extreme stress.
Thats what allows a mother to lift up car that has fallen on her child, a single Viking to destroy a whole crowd of his enemies and an angry XS11 owner to pick up that huge heavy engine.

[kjohnson]

Hi KJ,
hysterical strength, running amok, going berserk, there's lots of names for the phenomenon.

I think my favorite is hulk smash.

[bikerphil]

I put an engine in mine last summer, and did it with the middle drive gearbox off. It goes right in very easily not having to line up the u joint and worry about tearing up the boot. Mid drive takes about 10 min. to install afterward.

[fredintoon]

I think my favorite is hulk smash.

But there are drawbacks to that, like Kermit sez, It's not easy being green.

[co1954]

On my 82 XJ1100 I set a short piece of 2X6 on a floor jack then set the motor on the board, with my bike setting on the center stand I simply raised the jack till the board was flush with frame and slid the motor in.

[Ivan]

Wiggle, cuss, repeat.

That's what I did. It worked. The neighbors were embarrassed and some of them haven't come back yet.

I did use a couple 1 x 4s to help slide the engine in the right side. Laid them across the frame rail and an 5 gallon bucket so as to make a ramp of sorts. Getting the engine from the floor to the ramps was done via a rope, proper lifting techniques, some crunching sounds in my back, smashing my foot and tearing my jeans.

Not saying you HAVE to do it my way, but it worked for me.

[79XS11F]

I did my engine installation myself like this ... get the engine up to the right height and slide it into place on boards that are pull strapped to the frame. It was a piece of cake. Have the oil filter cover off of course ... If you don't have an engine jack use built up 4 X 4 or other item of about the right height that will support the weight of the engine. I used a bottle jack under the engine to remove the strapped boards. I suppose you could even set up longer boards that act like rails. Getting the height is important if it's going to just slide into place.



Rob