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Engine swap!!

  • Thread starter Thread starter UK-GT
  • Start date Start date
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UK-GT

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I have just got a spare engine and I am going to fit it soon, but what is the best way to do it, its a 673cc IL4 and not exactly light. Any tips would be welcome, I have done 125cc and 50cc engine swaps in the past, but this is a different beast!!
 
get a mate to help you is the easiest option, although it is not an impossible job to tackle on your own
 
How long roughly do you think it would take to swap it out & has anyone got any tips?

Cheers in advance.
 
Last edited:
UK-GT said:
How long roughly do you think it would to swap it out & has anyone got any tips?
Click to expand...
That depends a lot on whether you have help and how well-organized your work area is.

A couple of years ago, I returned from one of my work assignments about 11:30 on Sunday morning. By 12:10, there was help in the driveway and wrenches started flying. About 12:20 a second body arrived followed by more, at about 1:00, 2:30 and 3:00. We had the engine out of my son's 650L rather quickly, then had to remove the lower half of an engine from another frame and transfer it. Then we added the cylinders and heads that came in another box and re-installed the carbs that came off the first engine. Wasn't quite ready to fire at 6:00, but it wasn't due to the help I had, we were missing one part that needed to be replaced.

With one helper and a good work area, plan on at least 8 hours the first time around. As you get better at it, you can probably shave a few hours off of that.

The "help" crew included Cowboyup3371, Pano, Dogma, TheCafeKid, kparkfan and Mrs. kparkfan.
icon_thumbsup.gif


The bike has undergone a few changes since they saw it last, you can see the latest itteration by clicking on the link in my sig. Still a few details left, but it's rideable and he is saving for the last bit of stuff to be added.

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Take your time prepping the old engine to come out. Unless you're unusually lucky you can expect loads of seized bolts / nuts etc so give them a good soaking with penetrating oil etc a day or so in advance. The exhaust bolts in particular may well give you some grief - not so critical if you're not worried about snapping them off in the old head but you'll obviously need replacements to hand.
 
If you can find help, remove everything possible so the removal process will take the least time. Since it is a shaftie, that includes whatever that is connected to. Also the ignition, charging system, carbs, exhaust system, engine mounting bolts, etc.
While it is true they are not lightweights, I have installed the engine in my 750 GPz by myself before. I did it by installing the cylinder block after the engine was installed in the frame. So, if the cylinder block can be removed while in the frame, remove the head and cylinder block also.
 
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