Motorcycle teardown

[midnightcafe]

On some of the frames, and i dunno about yours, the 750s for sure, but there is a welded frame mount, so the motor can only come out one direction. It has been suggested that you can put an old tire down, lay the frame and motor over, undo the mounts and lift the frame away from the motor. Never tried this method, I simply get some extra hands and get it out upright. I would suggest, that if you try this, you drain the oil completely before hand.

thanks, I drained the oil against my dad's crazy notions that the pistons would seize over an oilless winter...
How many men would it take to remove the motor upright? I think I should look for a tire and place stacks of cardboard over it.

www.cb750cafe.com
I always check here for inspiration and some tricks but I haven't seen him tip a bike over to remove the motor. I dunno, I think I might keep it as is for when I return from school at thanksgiving seeing that I have to set up rearsets for a school project.

 

[Geoff4130]

This is a great thread! I kinda want to do the same thing, but I just got mine and it won't be too cold to ride for a month or 2.

 

[swanrogers]

Thank you!

Thank you!

So, I have to admit, Im a newbie, worked a lot on my car, havent worked on a bike ever, thank you for showing some pictures!!!

Question:

I need to replace my clutch, any way you are near doing that and could snap some pictures...a service manual never does justice!!

Thanks.
Ride Safe.

 

[Guest]

even if you lay the bike on the side, you'll still need another pair of (strong) hands
unless you re like extra super strong

 

[drhach]

I muscled my GS1000 engine in and out of the frame. Or, I guess out and in. I did it myself and it was a bear. That thing is heavy and awkward. My back was very angry with me when it was all said and done. I think you idea of laying the bike on its side is a good one. As Psyguy said, you probably will still need a second set of hands, but it will make getting it out really easy. I actually saw a video of Arlen Ness doing this and he made it look really easy. Just use lots of padding. Maybe even tip it over on to an old mattress just so you don't scratch, dent or bend anything.

As far as your Dad's comment about draining the oil goes, he's kind of right. If you're going to store the engine for a little while, take out the plugs and give the cylinders a shot of WD-40. It's cheap insurance. It's not whether or not there is oil in the crankcase or not as much as it has to do with not starting the engine and thus circulating the oil periodically. WD-40 sticks pretty good and so, it will keep that steel well lubed and it will burn off when you are ready to run the engine again.

Keep the posts coming.

 

[midnightcafe]

So, I have to admit, Im a newbie, worked a lot on my car, havent worked on a bike ever, thank you for showing some pictures!!!

Question:

I need to replace my clutch, any way you are near doing that and could snap some pictures...a service manual never does justice!!

Thanks.
Ride Safe.

try this:
http://www.youtube.com/watch?v=br63PLcq3sU
I won't be going into my clutch anytime soon. Of course I'll be getting help ripping the engine out, I can't really deadlift 230 pounds just yet

 

[TheRooster]

gs300 to a gs1000

gs300 to a gs1000

nice build

 

[drhach]

Since we're handing out tips. Here's a great way to inflate you tires.


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[Guest]

I muscled my GS1000 engine in and out of the frame. Or, I guess out and in. I did it myself

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!

 

[lecroy]

Not too bad if you remove the head, cylinder, pistons, starter..... first.

This may sound dumb but I normally put the bike on the motor. Pretty easy this way. I lay down some cardboard and carpet, put the motor on it and tilt it on its side. Then just lower the frame onto it. Frame is pretty light.

 

[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

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.

 

[Guest]

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.