Motorcycle teardown

[ryonker]

Great thread! Thanks!

I am also the proud owner of a 79 GS 750L. I am not going to tear it apart because she now runs great and is in great shape (also I am commuting with it) but it will be fun to see what she looks like all stripped down !

Looking forward to your progress.


Good luck!

Rick

[drhach]

then you must be one of those guys that i referred to as "super extra strong", cos that thing is over 100kg and in an akward position to get out from!

I think "Super Extra Stubborn" is probably a more accurate description.

[Smokinapankake]

Agree with drhatch. I laid my 82 Katana frame with motor over on the clutch side, setting the signal generator cover inside a large laundry detergent bucket. Removed all mounting bolts, and lifted the frame off the motor. Worked like a charm until I had to lift the motor off the bucket. Got my neighbor who, like me, is stronger than smart to help put it up on the workbench.

Amazing how quickly these things come apart, isn't it?

[hampshirehog]

I think I'd say that lifting the motor straight out is simpler but you need to eat an extra bowl of porridge in the morning.

Lying the bike on its side is a bit fiddly and takes longer but if you're not feeling strong / don't want to risk your back it's easy enough to do.

Either way, wrap your frame in old blankets and electrical tape to avoid taking the paint off.

[midnightcafe]

about done

I've decided to keep the motor on the frame until I get back from college at thanksgiving because of my rearsets project I mentioned in the first post. Otherwise, the bike parts are all organized and ready for restoration

[Matchless]

Just loosen the motor in the frame, jack it up a bit, slide two wooden rails under it and slide the motor out to the right side onto a same level box or your jack. Put it in the same way. No need for extra hands.

[jeff650gx]

So I'm still recording my process with the wiring harness and there's a couple of wires I need to get to behind the sprocket cover. BIG PROBLEM!

There's two screws under the clutch cover that need to be removed to fully take the sprocket cover off. the lower one came off easy with the impact driver; the top one didn't have the clearance for the impact driver. I did everything I could to remove that stuck screw, only to have the head stripped in the end.... I picked up a screw extractor today and took a go at it. I had to drill a pilot hole into the screw for the extractor to grab the screw which was difficult because there's so little clearance!! I drilled little by little until finally the extractor caught. I slowly turned the T-wrench until I heard a SNAP! looked at my tool, and the tip broke off!!!!! the screw extractor is made of high carbon alloy steel so there's very little chance you can drill it out. It's about a quarter of the thread, So what options do I have? luckily this only has to do with the sprocket cover and won't cause any bodily harm, but it will still slow my progress down


I've read bout EDM in the garage section, seems like the only option for this

There is a special tool made for removingbroken taps I've had luck with in the past. I'm not sure where to get them i borrowed. Maybe Grainger or a good tool supplier. good luck.

[psyguy]

Just loosen the motor in the frame, jack it up a bit, slide two wooden rails under it and slide the motor out to the right side onto a same level box or your jack. Put it in the same way. No need for extra hands.

yeah, this works well, but you need to take the head off first as otherwise the engine doesnt clear the frame when you jack it up, right?

[neeko]

not sure if its kinda late. But I just removed my 550 engine last week and thought this might help.

basically with the frame up right, I removed the engine mounts. As Thecafekid pointed out, the engine mounts are all removable on one side whereas they're welded in on the other side. For me the mounts were removable on the right side.

After removing all the mounts and bolts I simply wiggled the motor till it came loose of the frame and gently lifted it up so that the bottom end clutch side was resting on one of the frame rails. The next step is pretty easy

Just get a old tire or whatever and use lots of padding (old cardboard or whatever) and line it up next to the frame.

Now, while keeping the frame steady (have someone hold it down? or tie it down?) just pull the motor from the top side and it will tilt right out and onto the tire.

For me, upon listening to advice from my dad (for once HAHA) he suggested to put the tire on a moving dolly before pulling the engine out and BOY was he right! After engine removal it was just a simple matter of tilting it back upright and pushing it to whatever spot I wanted

Hope this helps!

[midnightcafe]

good info-seems to be the standard operating procedure on engine removal by yourself. I've already put the bike back together and would tell anyone thinking about doing so to cover EVERY frame tube that surrounds the motor. I got several scratches through my POR15 paint that I have to go back and touch up. This sucks because I had to reorder more chassis black paint which is expensive.

[gggGary]

FWIW I think it's easier to remove the engine when all the stuff is still on the frame wheels front end swing arm etc. It helps keep the chassis more stable. bike on the center stand. and pull the engine. Thread hi jack warning. will an 1100E head come off with the engine still in the frame?

[doctorgonzo]

FWIW I think it's easier to remove the engine when all the stuff is still on the frame wheels front end swing arm etc. It helps keep the chassis more stable. bike on the center stand. and pull the engine. Thread hi jack warning. will an 1100E head come off with the engine still in the frame?

Yes it will.

[DeafRider87]

I don't know if this is too late, probably is. Anyway, you can try use a dolly, just remove the mounting bolts from the side you're removing the engine from and then hold the motorcycle to the dolly and gently lower the dolly until the motorcycle is on its side then lift the frame off the motor. I never tried this before, heard about this from a friend of mine.