How to remove engine

[Guest]

So I did a search and was unable to find something that was along the lines of what I need...
Yesterday I tore the bike down to engine and frame with the intention of getting the frame powdercoated and a long road ahead of general tidying, polishing, etc.... I intend to go through everything with a fine toothed comb and come out on the other end with a new looking Katana.

So the first major stumble (not really stumble, just a few tips, pointers, or whatever wisdom you all have to offer): How do I remove the engine from the frame? My factory manual was a little vague.... I don't have an engine hoist, I don't have a come-along, I merely have a 2 ton floor jack and some jack stands. And possibly can find a few other fellas with strong backs and weak minds...

Any help is super appreciated.

[Smokinapankake]

Oh yeah, 82 Katana 1000.

[Suzuki mad]

Version 1.
Place jack under engine, undo bolts, remove all the engine retaining brackets then man handle the beast out via the right hand side with two strong mates and a few beers after wards.

Version 2. Strip the rocker, cylinder head and barrels off the engine in the frame then undo the bolts and retaining brackets. Its SO much lighter and easier on the back.

If it were a Z900 you lay the frame on its side with the engine in then remove the frame from the engine. Never tried that on a Suzuki though.

Suzuki mad.

1981 GS1000E
1983 GS(X)1100ESD
2002 GSF1200K1

[Smokinapankake]

I was thinking along the lines of laying it on its side too, but don't know if anyone else has tried this method yet. I may end up pulling the head and jugs off as it seems easier and since I'll be in there anyway I might as well have somehing to hold the bottom half in place, eh?

[Nessism]

This issue came up recently in the GS Motorcycle Discussion forum so you might want to do a search. Several people recomended laying the bike on it's side. I've never tried it but can attest to the weight of these GS engines.

[nabrams]

Getting the engine out will be easy compared to getting it back in. I had to do it alone with just floor jacks. Took me hours and I got filthy, sweaty and bloody. Find a friend who owes you one and get him to help.

[BassCliff]

Side by side

This issue came up recently in the GS Motorcycle Discussion forum so you might want to do a search. Several people recomended laying the bike on it's side. I've never tried it but can attest to the weight of these GS engines.

Good memory Mr. Nessism. I also remember something about using a loose tire or two and a few strong friends. Here's the thread of which we speak.

Thank you for your indulgence,

BassCliff

[Smokinapankake]

Thanks for the link, Basscliff. I did a search but for some reason didn't see that one. Next question is what is a good way to clean engine and paint? Do I need to tear the whole thing down to give it a good solvent douche or can I just plug the intake and exhaust holes, hose down with degreaser and then wash liberally? I'd like to paint it also, just wondering what a good method would be. Don't really want to tear it apart beyond clutch, signal generator, stator and sprocket covers. Those parts will be polished and then clearcoated. Any Suggestions?

[Suzuki mad]

Best and longer lasting way is to strip it right down, crank out, valves etc and have the cases, barrels, head, rocker box cover all bead blasted and then powder coated. Its a real time waster doing all the masking up but the finsh will be amazing. (Check out Classic Motorcycle and Mechanics if you get the mag.)

I did see a bandit engine in the blasters last year with special exhaust covers, the breather taped up and that had been sandblasted and primeured but can't say to how good the engine was afterwards.

If you can only afford the hand wash way then thats lots of bottle or test tube cleaners and dirt remover.

As for paint, I believe that Suzuki engine colour is an unknown variant that people have used what they can get thats the nearest to silver. Its easier with the black engines as paint shops have the colour codes for those.

Suzuki mad

[Smokinapankake]

So it's been a while since I posted or even visited GSR, but I have a bit o news: Sunday aftenoon I had some time to myself and I thought "what the he11, I oughta try getting that motor out". So I removed all the mounting plates and bolts except the two at the top and bottom rear of the gearbox, got one of those 5 gallon buckets you get laundry detergent in (like at Sam's Club), set it next to the motorcycle (engine and frame sitting on jackstands) and laid the bike over on the right side. The bucket held the engine (with the signal generator down in the bucket), I removed the last two mounting bolts and plates, removed the breather cover, and lifted the frame right off. It was the easiest thing in the world.
Next, I thought "what the he11, might as well get that engine off that bucket before it falls off", so I wrapped both my arms around it, and staggered over to the workbench with it. Couldn't get it onto the workbench, though, so my neighbor came to my rescue. So now it's ready to come apart and prepare for painting...Yay!!

Seems like the more involved you get with these motorcycles the simpler they are.

So I can attest to the viability of laying it on its side and removing the frame from the engine, if anybody wants to know....