Engine Installation Help Required

[Benno #03]

Hi Everyone,
I'm a bit stuck, I'm no mechanic but have the necessary tools/equipment required.
I got caught in one of those stories everyone has heard.
I had my 350LC engine rebuilt, and the shop closed its doors half way through the build and I got it back in pieces.
I have since had the engine rebuilt and have it on the bench and the bike on a hydraulic bench.
I have no one that can assist me(I live in a remote town in Nth Wst Australia, Broome).
I was hoping there may be some installation videos or instructions you could advise me off.
I'm told fitting the engine is a one man job, but for the life of me I cannot lift and position the engine to get it into the frame by myself.
I have a heap of questions like.
Can I fit it in it's complete stage or do I need to remove carbs, or heads etc.
I will post pics later when it's daylight here.
Any help or advice would/will be Greatly Appropriated.
Thank you for taking the time to read my delema.
Cheers Benno.

[silverstrom]

You need the kick start lever attached to the engine.

Cover the lower frame tubes with something to protect them from damage. Foam insulation (tube) meant to cover household piping works perfectly.

Place the engine on a stand at the same height as the frame opening.

Your right hand grabs the kick start lever and your left grabs the engine case above the stator (cover off, of course).

Place the engine in position in the frame. The frame tubes should be be covered and protected, so and you can rest the engine there if necessary.

That is the easiest way I know how to do it.

[Smoker]

There are many guys around here that can give you better advice than I, but here's what I've got.

Carbs off, head can stay on.

When I remove and install the engine, I don't want to scratch up the engine or the frame.

First, I put plenty of masking tape on the frame, because the engine is probably going to make contact somewhere in the process. Not one layer. At least 5 layers.

Second, I build a simple platform. Maybe just a milk crate with a couple of pieces of wood on top. The idea is to get the height about 1/8" higher than the lower frame rail.

Third, I have a piece of wood cut to fit inside, between the lower frame rails. I place the wood on a jack and jack it up from under the bike until the wood is the same height as the platform.

Then, I place the engine on the platform and carefully and slowly slide it over the gap. It needs a little twisting and turning, but it's not difficult, and it will keep the nice parts looking nice.

[JonW]

Its defo much simpler if you have a person who can help, even better if they are strong enough to do the lifting and you guide it into place and push the bolts in. The engine is about 35kgs and anyone lifting it on their own needs to be able to hold it for a few mins.

You can and should put some rags on the frame rails. tape em round etc.

Have everything ready. Plates, bolts etc. before you start. move things out of way like rev ctr cable, temp sender and spark plug cables.

One person picks up engine and offers it in from the right, the other person guides from the left and is in charge of bolts/plates etc

Engine is lighter without flywheel and that gives you the end of the crank to help guide it in. tape over the woodruff key hole so it doesnt almost chop off your finger... ask me and LB how we know that. Fair play tho, I ignored the gushing blood and we finished the job before seeking medical attention lol

Defo carbs off. Leave the plugs out too, just put some tape over the holes.

Ive done these on my own and with others, I would always choose the latter, even if you do the lifting and advise a non bike person what to do. Helps to show them with dry run first, ie this bolt slides in here and this plate goes this way round etc

Dont forget the engine dampers on FL and RR when you do it. The banshee ones are better than the RZ if youve lost them and need new ones.

Good luck Benno, wish i was local mate, I'd pop over and we'd knock this over in mins.

[Benno #03]

Thank you all so very much.
That advice is extremely helpful and gives me a new lease on getting the job done.
Cheers Benno.

[hablair]

I envy you in such an awesome place as Broome, Ive been there on quite a few occasions and north of it too up the Gibb to Drysdale and Mitchell falls, really need to get back there - one day

It should be getting nice and warm now, I work between Pannawonica and Hedland and live in Perth

As said above get some 1” foam tube, even a couple of pool noodles will do, cut through the foam along the length and feed it onto the frame, top and bottom rails, and use masking tape to secure it in place, that will save your paintwork

Use the milk crate tip and the jack and plate trick from above and your done, perhaps using a sheet of acetate to allow the engine to slide in from the crate to the cradle in the frame

Two pairs of hands are always better than one

Have fun

Howard

[kpke]

When you are have no friends you must learn to do it yourself It's really quite simple.

I took some photos last time I did this.

See post #102.


viewtopic.php?f=5&t=16233&start=90

[85RZwade]

As if there aren't already enough good ideas here:
Lay frame on floor on its side
Lower engine into frame
Install motor mounts
Lift frame upright
Voila!

[brrrappp]

As if there aren't already enough good ideas here:
Lay frame on floor on its side
Lower engine into frame
Install motor mounts
Lift frame upright
Voila!

Now that's the kind of thinking I expect from a real motorcycle guy.

[85RZwade]

Many thanks, and you're welcome (imagine I'm bowing deeply, yet keeping my eyes on my adversaries like Bruce Lee)

[Smoker]

As if there aren't already enough good ideas here:
Lay frame on floor on its side
Lower engine into frame
Install motor mounts
Lift frame upright
Voila!

If I had my choice, I'd rather lower the frame onto the engine, than the engine onto the frame.

The frame is about 1/3 the weight of the engine.

[85RZwade]

Good point! That engine must be nestled securely in the frame now

[Hooligan]

Just to be clear, the engine slots in from the right side of the frame. Can't go in the other way.