engin swap????

[timeless-cowboy]

well guys i had a problem with my 1980 xs1100 and there was a loud pop like a bolt broke in side , i could here it roll down in side the motor and then it locked up . ok the question is to change the motor out do i have to take it apart all the way to get it out ? or is there a barcket that just comes lose to help with the removel?
.... sorry for all the questions ,i just thought since i have a spare frame with the motor on it i would just switch it then rebuild the other

thanks for the time in advance

[DGXSER]

Hey Cowboy,

As to the actual engine, I have watched soem of this process before. Others with real expereience will chime in I am sure. The only thing I recall needign to be removed is the valve cover and the oil filter cover.

Now it would get alot less crowded in the frame if you pull the head off, and I probably would with the engine you think is trash. And of course there are numerous wires and such that need to be pulled. as well as the carbs exhaust and the coupling at the output of the middle drive.

As to what holds it in the frame, there are roughly 5 places I can recall off the top off my head where it is bolted in. The rear through bolt that holds the foot pegs on as well, and in the front there are upper and lower mounts on each side of the bike. I might be missing one in there.

You should definitely get a manual and read through it first though and follow the steps carefully one by one. A long time ago I had a VW bug with a bad clutch, so I pulled the engine to replace it (as is the process on those vehicles) and when I got to the step on sliding the engine off the tranny, I had to pull and tug VERY hard to get it lose. After I got it out, I realized I had forgotten to remove the heater control cables and snapped them. From then on I had full time heat in that car!!

[timeless-cowboy]

thanks for the info i have done a little work on the bike but never pulled the motor befor so i didnt know if there was an easyer way than the way it realy looked ... like taking the head off and ect.
well i guess i need to getter dun now , thanks againg for the tip

[trbig]

Yup.. as he said with the carbs and exhaust. And as he stated, the filter cup needs to come off to make room. There's two brackets in the front of the motor that connect the motor to the frame. 2 bolts each in those, then a long bolt goes through both those brackets, the frame, and the motor. One more mount on each side below those, then the long one that holds the rear and the pegs.

Pulling the head right now is just extra work unless you have to. It will come out just fine with it on, and you'll be able to split the cases with it in place as well. You will need to remove the valve cover for clearance though. I don't like pulling the head first, personally, because the threaded part of the studs catch on every box and wire on the way out. The motor is heavy enough that it pisses me off to pick it up and put it down several times to remove a wire it's caught.

Pull back the rubber boot and remove the 4 bolts going to the U-Joint/Driveline and disconnect all the wires around the motor, including the positive wire going to the starter. That part was scary to me the first couple times, (Removing all the connections) but all the connectors are unique and can't be messed up. There's one tiny wire that's easy to miss on the bottom left side of the oil pan.. one tiny phillips screw removes it.

When you're ready, if you have a floor jack, jack up the motor a couple inches to get the bottom mounts out of the frame, spin the motor so the tail is out the left side..be very carful about the rubber boot.. it likes to get caught here. .. and take the motor out of the right side.

Do you know anything about the donor motor? Maybe a good time to do the gear fix while it's out of the bike.

Good luck.. and if in doubt, jump on here and ask quesions. If something locked up a spinning motor, there is going to be damage. I hope it's minor.


Tod

[DGXSER]

I agree with Tod (OMG that is twice in the same year )

Unless you know the details of the replacement engine, before you put it in the frame, check the gears. Depending if you pull the gears to check them, it will also let you check the clutch and that the oil pump drive gear is on the shift fork shaft properly something I have seen a few times lately on "spare" or long storage engines. If you pull them, by all means grind them if they have not been.

Also run a compression check on the replacement engine before you put it in place as well as shim the valves. Much easier to find and replace a bent valve if needed or simply replace shims with it out of the frame IMO.

[cywelchjr]

I would agree with a lot of it, but I didn't pull the valve cover on either engine when I changed mine, and it didn't seem hard t me. (yes I know you do have to pull it after it's in, but I haven't broken down the old one at all yet).

I did however have the oil filter cup off, but the oil cooler assy was still on the replacement engine when I put it in (I took it off after as I haven't figured out where to mount the cooler with my fairing yet).

[timeless-cowboy]

well thats more info over all than i hoped for LOL , thanks againg guys it will be a bit befor i take on this mission, so im just trying to mently get ready for a lot of MF's and GD's while doing it and a few new words as well.
i doe have a good varity of jacks and tools so i think i good there i just have never pulled the motor on a bike , cars and pickups ect np

i will refer to you guys as offten as needed and do you reckamend 2 man lift on the motor ?

[Ivan]

Man, these guys are making it too complicated.

1. Drink a six pack, or more if you feel like it.
2. Start taking out bolts until the engine falls out. Start with bigger bolts first.
3. Drink more beer.

[crazy steve]

Man, these guys are making it too complicated.

1. Drink a six pack, or more if you feel like it.
2. Start taking out bolts until the engine falls out. Start with bigger bolts first.
3. Drink more beer.

I got mine out of the 'parts' bike without pulling either the valve cover OR the oil filter; it was a tight squeeze, but it came out.....

'78E original owner