SuzukiSavage.com /cgi-bin/YaBB.pl General Category >> Rubber Side Down! >> Engine removal tips, techniques, gotchas? /cgi-bin/YaBB.pl?num=1223165809 Message started by Rogue_Cheddar on 10/04/08 at 17:16:40

Title: Engine removal tips, techniques, gotchas? Post by Rogue_Cheddar on 10/04/08 at 17:16:40 I think I'm going to shutdown early this season and work on various parts of the bike, spruce it up for next season. I looked for a specific tech link on engine removal, but didn't find anything. So I'm asking all you hardcore grease monkeys here,for any tips, techniques, gotchas, and what have you, as I boldly go where no Cheddar has gone before. Thanks in advance. I've been whacking the back of my knuckles this past week, in preparation.  :D

Title: Re: Engine removal tips, techniques, gotchas? Post by rigidchop on 10/04/08 at 21:40:57 justmake sure you label everything. it took me twice as long to put mine back together.

Title: Re: Engine removal tips, techniques, gotchas? Post by mick on 10/04/08 at 22:58:42 Get the "Clymer" manuel, read as you go.  and keep things neat and clean and labeled.

Title: Re: Engine removal tips, techniques, gotchas? Post by justin_o_guy2 on 10/05/08 at 09:20:26 The only "Gotchya" I know of is the "Cable Hanger" on the clutch.Where the clutch cable attaches to the lever down on the case, that little "swinging Box" will be hanging Down ( if left to its own devices) & you will either have to mangle it a bit( thats what I did) or pull a lot of stuff apart, to rotate it into position.

Title: Re: Engine removal tips, techniques, gotchas? Post by justin_o_guy2 on 10/05/08 at 09:34:18 I use cardboard for keeping up with bolts.I still have the ones Ive needed sp far. If you pull one side of the engine off, draw to general shape of the case & mark along the line where each bolt goes, some have special rubberized washers, others dont.( gotchyaz!), poke a slot with your knife & put each bolt in its place, makes going back together a breeze. When the cardboard thing isnt practical, I put bolts back in holes they came out of, or at least with whatever they held on the bike. No nuts or bolts are just left laying around, they WILL be associated with something to help me remember hopw it goes together. Meticulous disassembly, using notes if necessary to help remember what parts go where, & a clean workspace, will pay back the extra time spent in disassembly by making it so much less stressful going back together. Someone wrecked our CamCorder, I took it apart, ordered the parts & waited, parts came about 6 weeks later, but I didnt have time to mess with it. I got around to it about a year & 1/2 after taking it apart. I had put screws with their associated parts, & had set subassemblies together. It took about 2 hours & it works, still. Its all about clues, leaving ourselves clues. I write myself notes & tape them onto things under the hood of a car, Just in case something takes longer than expected..I use wide tape, so the notes are safe from grease & stuff, too. People may laugh at the anal way I do things, BUT, those who would laugh AT the way I keep from shafting mysel;f couldnt come help me if I couldnt remember. Do it the way that YOu KNow you can find the parts & put them where they belong.

Title: Re: Engine removal tips, techniques, gotchas? Post by YonuhAdisi on 10/05/08 at 11:40:25 Take it slow and keep a repair manual open in front of you the entire time know matter how good of a mechanic you are. Label parts, make rough diagrams if you have to. Like the that old tale about the rabbit and the turtle, slow and steady wins the race, if you rush, it is almost guaranteed that you will mess something up.

Title: Re: Engine removal tips, techniques, gotchas? Post by KwakNut on 10/06/08 at 08:04:07 322D2B2C31360737073F2D216A580 wrote: I use cardboard for keeping up with bolts.I still have the ones Ive needed sp far. If you pull one side of the engine off, draw to general shape of the case & mark along the line where each bolt goes, some have special rubberized washers, others dont.( gotchyaz!), poke a slot with your knife & put each bolt in its place, makes going back together a breeze. When the cardboard thing isnt practical, I put bolts back in holes they came out of, or at least with whatever they held on the bike. No nuts or bolts are just left laying around, they WILL be associated with something to help me remember hopw it goes together. Meticulous disassembly, using notes if necessary to help remember what parts go where, & a clean workspace, will pay back the extra time spent in disassembly by making it so much less stressful going back together. Someone wrecked our CamCorder, I took it apart, ordered the parts & waited, parts came about 6 weeks later, but I didnt have time to mess with it. I got around to it about a year & 1/2 after taking it apart. I had put screws with their associated parts, & had set subassemblies together. It took about 2 hours & it works, still. Its all about clues, leaving ourselves clues. I write myself notes & tape them onto things under the hood of a car, Just in case something takes longer than expected..I use wide tape, so the notes are safe from grease & stuff, too. People may laugh at the anal way I do things, BUT, those who would laugh AT the way I keep from shafting mysel;f couldnt come help me if I couldnt remember. Do it the way that YOu KNow you can find the parts & put them where they belong. Very good advice, especially the cardboard trick, which is ideal for jobs like the Savage head cover.

Title: Re: Engine removal tips, techniques, gotchas? Post by Rogue_Cheddar on 10/07/08 at 17:28:25 Thank you all for your replies. This is still the best frickin site evah! I have my Clymers and and found some old cardboard box I can use. It had some old fancy white wedding dress in it, which I tossed. Should be perfect for the job. Wish me luck!  :D

Title: Re: Engine removal tips, techniques, gotchas? Post by verslagen1 on 10/07/08 at 18:03:56 should keep the dress... yours hands are gonna get dirty.   ;D

Title: Re: Engine removal tips, techniques, gotchas? Post by Rogue_Cheddar on 10/11/08 at 15:11:57 A couple of last questions, are you guys dropping the engine down through the frame, lifting the bike over it, or do you pull it up and out through the side? Looking for the least physical stress on my back. Also what are any of you using to hold the bike up while you work on it? Wheel chock, or straps hung over ceiling beam?

Title: Re: Engine removal tips, techniques, gotchas? Post by justin_o_guy2 on 10/11/08 at 15:18:21 If I was more concerned about spending back muscles than time, Id set the bike up under something I could rig a sling under, set the emgine down with the sling & hoist the bike up & swing it to the side, set it down, Get back on the engine, lift it into a wagon or something & then hoist it onto a bench. Old crippled up guys can DO the work, it just takes longer.

Title: Re: Engine removal tips, techniques, gotchas? Post by YonuhAdisi on 10/11/08 at 15:58:47 7D40485A4A706C474A4B4B4E5D2F0 wrote: A couple of last questions, are you guys dropping the engine down through the frame, lifting the bike over it, or do you pull it up and out through the side? Looking for the least physical stress on my back. Also what are any of you using to hold the bike up while you work on it? Wheel chock, or straps hung over ceiling beam?   I usually use a couple of ratcheting tie downs attached to the ceiling beams and the handle bars to keep the bike up right. To get the engine out after disconnecting everything and just grab a hold of it and wrestle it out the left side of the frame.

Title: Re: Engine removal tips, techniques, gotchas? Post by justin_o_guy2 on 10/12/08 at 08:26:46 WILL this engine pass thru? Can it be dropped down? What is the easiest, least amount of physical exertion method? Rogue is trying to save lower back from getting clobbered.

Title: Re: Engine removal tips, techniques, gotchas? Post by verslagen1 on 10/12/08 at 08:40:40 won't drop thru easiest way? get the wife to do it.   ;D

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