Engine removal

[81xsproject]

Okay, so I am lazy. I am curious as to whether or not the entive engine/trans unit can be removed from the frame so I can clean and paint the frame. If not, what is the minimum disasembly required?

[Dennyz]

I removed my engine (and tranny) to paint it. I used the following steps (the best I can remember):

- Remove the battery
- Remove the fuel tank
- Remove the exhaust system (all of it)
- Remove the airbox, carbs and throttle cable (store out of the way)
- Unhook the clutch cable and store out of the way
- Unbolt the Ujoint and push it towards the rear
- Remove the Ujoint boot
- Unplug ignition wires and store out of the way
- Unplug the wiring harness and oil sending unit
- Drain the oil
- Remove the oil filter unit
- Remove the muffler/passenger peg mounts on the right side

- If you are doing it by yourself -

- Lay the bike on it's left side, supporting the frame with four jack stands
- Wrapped two motorcycle tie-down straps around the engine
- Lift engine out of frame with an automotive engine puller

- Otherwise -

- Leave bike on the centerstand and have a couple of strong buddies wrestle it our of the frame.

- Reverse the process to install the motor -

Note: The motor weighs in right around 200lbs.

[dntemp_ca]

Alternative. Maybe. I thought I read somewhere on the forum about an XSive who pulled the engine by laying the frame and engine down on its right side and lifting the frame off (lighter than engine). I don't know if it works, but makes a lotta sense if you're working alone.

[Dennyz]

The rest of the bike weighs as much or more than the engine and a lot harder to manage (IMHO), but it should work.

[xssiveone]

Originally posted by dntemp_ca
Alternative. Maybe. I thought I read somewhere on the forum about an XSive who pulled the engine by laying the frame and engine down on its right side and lifting the frame off (lighter than engine). I don't know if it works, but makes a lotta sense if you're working alone.

Frame is way too heavy to do this by yourself IMHO. I did this to reinstall the engine after a frame paint. Wrapped the frame with rags to prevent scratching it.

Gary (66) removed his by laying it on it's side and wrapping a strap around it attached to a winch of some kind.

I removed mine with a friends help, slid it out onto a platform the same height.

[81xsproject]

thanks for the advise guys. I thought it looked like I should be able to pull it out as a whole, but the book gave instructions for disassembly and I usually find out the hard way that the manual was right.

[beechfront]

i laid the bike on the side and winched the engine up and out.


worked pretty good.

[skids]

I did it that way also to swap engines bike to bike. I did it by myself, but I wish I would have waited for help to arrive!!!

Originally posted by beechfront
i laid the bike on the side and winched the engine up and out.


worked pretty good.

[81xsproject]

New questions...
now that it is out and I have done my best to clean/degrease the enjine w/o disassembly, does anyone have any good suggestions for pre-paint prep and reinstallation w/o scratching the crap out of the newly painted frame?

[xssiveone]

Originally posted by 81xsproject
New questions...
now that it is out and I have done my best to clean/degrease the enjine w/o disassembly, does anyone have any good suggestions for pre-paint prep and reinstallation w/o scratching the crap out of the newly painted frame?

This works if you haven't assembled the frame yet. Lay the engine on it's side and wrap the frame with towels or rags. With someone's help, lower the frame over the engine. Put the bolts in place and then stand the frame back up.

If you've already assembled the frame, then just wrap with towels and hope for the best.

[randy]

Other than degreasing, you might want to wire brush it to get the loose paint off before you re-paint the engine. Then spray it with a high quality hi-temp aluminum paint.

Assuming youv'e already got the frame re-painted, when you're ready to re-install the engine, lay the engine on it's side. Install the center stand on the frame. Lower the frame onto the engine. Get a couple of mounting bolts run in and then you can turn the whole thing upright, install the fork. The rest should come naturally!

Don't kid yourself, you will have to touch up some minor dings on the frame.

This is basically the way I did mine all by my lonesome.

Have fun!

Randy