Here's a short simple tutorial showing you the steps needed to remove a motorcycle engine from the frame. The procedure shown in the video is on a 1985 Kawasaki GPZ 750R/ 900R. But this procedure is largely the same for almost any bike and differs in that it is slightly simpler for air-cooled and single-cylinder motorcycles. The difference is also that v-twin engines usually have to come out the side of the frame while four cylinders usually drop straight down.
The steps are:
1. Remove fairings (if any), tank, seat and battery
2. Disconnect coolant hoses and drain the coolant (skip this step if removing the engine from an air cooled motorcycle, obviously).
3. Disconnect and remove the radiator. Be careful of possible ground connections on the radiator, so you don't rip the wires apart.
4. Drain the oil from the engine and the oil cooler
5. Disconnect oil cooler hoses and remove the oil cooler as well as any sub-frames used to house the oil cooler and radiator
6. Unbolt and remove the headers and exhaust(s)
7. Depending on the motorcycle you may need to remove the footrests as well
8. Remove the carburetors (throttle bodies and injectors) and the airbox. Carefully disconnect choke and throttle cable ferrules.
9. Remove alternator, starter, ground and any other electrical connections to the engine
10. Disconnect the clutch hose
11. Remove the chain (belt) cover and front sprocket cover
12. Unstake the nut and remove the front sprocket (if possible)
13. If removing the front sprocket doesn't work, remove the rear axle and wheel and remove the chain.
14. Locate all bolts that hold the engine to the frame
15. Support the engine from below using car jacks or similar
16. Wiggle the engine around and get it out of the frame
17. Pat yourself on the back
As you can see removing a motorcycle engine from the frame is a relatively simple DIY job. It can be time-consuming and tedious, but it requires no specialized tools and can be done by almost any willing motorcycle DIY enthusiast.
#d4a #motorcycle #diy