Mounting the engine on the frame

[RichV]

I've been alone here for a few days while my family is off doing other things. I finished the engine and wanted to put it on the frame without causing any damage. This is how I did it.

I have the bike on a raised platform and the engine on a table. I put them side-by-side at the same level and put a board between them. I protected the forward part of the frame with a 2x4. The engine wants to rock forward since I don't have the middle gear installed.

I then lifted it off the board with a hoist and some straps. It lowered into the frame without a hitch. No scratches. No strains.

The strap was there to hold the bike stable while I moved the platform around.

Here are some photos of the process.

[Gmac]

That platform

looks like it makes working on the bike a lot easier than doing it on the floor.

[RichV]

I got it from Harbor Freight for $299 on sale (insider club). Best purchase I've ever made for working on bikes.

The guy at Harbor Freight told me he's never had one returned. I can see why.

I love working on a bike at eye level. Saved my back.

[donebysunday]

How flat does that hoist get ? Got to tuck it under the boat.
What did you use on the engine cases looks great !
The bike looks like it will come out like new !

I got it from Harbor Freight for $299 on sale (insider club). Best purchase I've ever made for working on bikes.

The guy at Harbor Freight told me he's never had one returned. I can see why.

I love working on a bike at eye level. Saved my back.

[b.walker5]

God Damm thats a shiny engine....

[trbig]

*Sigh..... Now take it back out.


Cylinders/head won't go on with the motor in the bike. Sorry...

[RichV]

I took it off while it was on the bike. It will go back on.

I used the weight of the engine and frame to help me pull it off the engine.

[trbig]

*Shrugs...

OK. I have gotten the head on/off, but the clearance is so tight between the frame/top of studs, the studs end up putting scrapes in it to get it there. The cylinders weren't even close for me. I don't think the cradle area holding the motor is different between XS/XJ is it?

Anyway, good luck. On a workbench, installing the pistons/wrist pin clips is hard enough. Getting the piston rings compressed and slid up into the cylinders without breaking any of them, even worse. Doing this in the bike frame? Not me.. lol. Don't forget your big orange O-rings around the base of the cylinders. If using a base gasket, I would recommend some additional liquid gasket of some sort since they have a tendency to leak there.

Great idea on the cylinder removal. Lots of fins have been broken by people trying to remove them.

[PMKXS11]

*Shrugs...

OK. I have gotten the head on/off, but the clearance is so tight between the frame/top of studs, the studs end up putting scrapes in it to get it there. The cylinders weren't even close for me. I don't think the cradle area holding the motor is different between XS/XJ is it?

Anyway, good luck. On a workbench, installing the pistons/wrist pin clips is hard enough. Getting the piston rings compressed and slid up into the cylinders without breaking any of them, even worse. Doing this in the bike frame? Not me.. lol. Don't forget your big orange O-rings around the base of the cylinders. If using a base gasket, I would recommend some additional liquid gasket of some sort since they have a tendency to leak there.

Great idea on the cylinder removal. Lots of fins have been broken by people trying to remove them.

I pulled my head and cylinders with em still in the frame. It is a tight squeeze, but if you take your time and are careful, it isn't that bad.

[Pat Kelly]

I did the 1196 kit on my LG with engine in the bike.

[RichV]

I got the pistons and cylinders back on today.

[mack]

Cases

Rich what product did you use to mate your cases together? I got 3 bond bond but it says to slather the surface with a paint brush and I was looking to just put a small bead on and let it squish into place to avoid dripping inside and out. Also did you run a bead under your base gasket?

[RichV]

I used Threebond 1184 on the case. I've used it before as a gasket replacement.

In this case, I used it to seal the case and on the middle gear gasket, the base gasket and the head gasket. I like to add it to permanent gaskets in order to fill in any unevenness.

On the case, I place a bead on both halves and spread it with my finger (in a glove) to cover the entire mating area. A little bit may squish out but that should be okay once it's cures. Just keep it off the bearings.

On gaskets, I place a small amount on both sides. Not as much as the case.

If I think I need to get into a part of the bike again (like the clutch) I will spray the gasket with Pam which makes it more pliable and it doesn't stick.

[mack]

Pam

Ya, I use the BBQ Pam on all my cover gaskets as well. Beautiful motor by the way. For the time it takes when it is out of the frame and apart, why not make it spotless.

[trbig]

For the time it takes when it is out of the frame and apart, why not make it spotless.

'Cause most of the time I'm in a hurry to get back to riding it! lol.. Seems like about every motor install I've done, I've finished either the night before or the morning of some long ride. Trial by fire I guess. Always made it there and home when I can stay away from the guardrails.. lol.