Engine Removal
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Thread: Engine Removal

  1. #1
    AMA Pit Boss Moyston's Avatar
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    Engine Removal

    I ended up searching a few threads on engine removal and dos and donts etc, and in the end..i thought bugger it..ill do it as per the manual. So I ended up picking this TL up as it has spun an output shaft, and its cactus. I've had a spare engine for a while that I managed to put together learning all about it. First engine I did take apart and put it all together. the test will be if it works....
    So I thought what better time to take it out, and put the other engine in....the aim is to turn it into a trackie....sold the gixxer trackie today..........which gave me some space...just go out tomorrow and get front wheel stand
    So i started off with this....

    with the aim to put this in...

    read this....


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  2. #2
    AMA Pit Boss Moyston's Avatar
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    got all the tools i had lying around...got a friend to help...

    began to take it all apart starting with fairings and tank. placed all screws and bolts etc into little marked bags, and then because this will take me a bit of time to do, pulled wires apart and labelled so as to know were they will go back in time..


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  3. #3
    AMA Pit Boss Moyston's Avatar
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    got all bits taken off, and now up to removing the fluids....and called it a day...


    its amazing when you take someone else bike apart.(mine now ) ..i had plasterers screws holding the under tail on, the under tail has been cut to fit a clear stop light in it, but has been joined together with a ton of black silicon.... I had wood screws holding indicators on, and some nut I dont know were from sitting in the battery tray....what i did find was that he has upgraded the lights and fitted some HID ballasts


    so that will do for today.....


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  5. #4
    Platinum Subscriber JoshCampbell's Avatar
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  6. #5
    AMA Pit Boss Moyston's Avatar
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    OK, so next was up after brekkie to tackle the fluids...first was to drain the oil...he said the output went when he was riding...this is all that came out of the engine...any wonder...

    at least when it was starving, it wasnt hot...


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  7. #6
    AMA Pit Boss Moyston's Avatar
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    next was off with the airbox..he had a pipecross air filter in there. the actuators that are held down with the screws and have those little bent tabs over them...all broken ..

    more labelling. if i didnt do that..id be knackered trying to remember to get it all back together...

    throttle cables, a bit dirty and grimy....these arent to bad to get out...

    but the rev limited..that is a nightmare to get out...little jap hands are only going to fit in there...


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  8. #7
    AMA Pit Boss Moyston's Avatar
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    ok, all marked and throttle bodies all removed...

    now to remove the rear engine exhaust bolt....oh dear...

    next the front header bolts..wasnt looking forward to this..Ive already busted a head a while ago putting on a yoshi...not fun..so lubricated, then heat, and again, then attempted to budge...no would not move at all...both of them...so i wasnt going to try and just left them and tackle when engine out.

    took the exhaust apart and left the left hand side all connected.
    so no exhaust left side and all marked..ready to tackle engine bolts


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  9. #8
    AMA Pit Boss Moyston's Avatar
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    everything disconnected, all cleared. only thing holding on is the loose engine side bolts and that castle nut. Was going to make one as others have..took the nut off, then the large castle nut, then the main one...just gave few taps with screwdriver..couldn't wait and was fine and no damage...sorry no trying to get engine out pics
    I ended up using a car jack and resting it on the oil filter, fitted nice, raised it to the front began to lift...then pulled all the bolts, apart from the rear one so it could rest on it, then lowered the jack....the engine came down. It does get stuck, and you have to wiggle it to the left and keep doing it...its the rear exhaust that gets stuck in the hole in the frame and can become stuck. ..in the end, it worked well...
    next time, ill get a head stand as i couldn't wait as the shop was closed today...with no stand on front wheel...it really didnt have to drop a lot. then I lowered the rear stand, which lifted the rear out, then put the rear stand on again, and raised the bike and engine eased out...

    here it is..with left exhaust still fitted...get to get those bolts out, but at least can get to them from the front instead of on my back....

    and in the end..you end up with a pile of fkn spaghetti


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  10. #9
    AMA Pit Boss Moyston's Avatar
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    so now ill tackle the header bolts at a later stage , or cant be stuffed and just cut the exhaust off at the engine...now got to look up ways to get this other engine in....thats going to be a bit harder i rekon....


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  11. #10
    GP Champ dadat178's Avatar
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    You've been a busy boy Dave, nice write up. Does the new motor know it only needs first and second gears
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