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Operations requiring engine removal

It is necessary to remove the engine/transmission from the frame to gain access to the following components:

Pistons

Cylinders

Connecting rods and bearings

Balancer shaft

Camchain

Crankshaft and bearings

Transmission shafts and gears

Selector drum and forks


4 Major engine repair-

general note

1 It is not always easy to determine when, or if, an engine should be completely overhauled, as a number of factors must be considered.

2 High mileage is not necessarily an indication that an overhaul is needed, while low mileage, on the other hand, does not preclude the need for an overhaul. Frequency of servicing is probably the single most important consideration. An engine that has regular and frequent oil and filter changes, as well as other required maintenance, will most likely give many miles of reliable service. Conversely, a neglected engine, or one which has not been run in properly, may require an overhaul very early in its life.

3 Exhaust smoke and excessive oil consumption are both indications that piston rings and/or valve guides are in need of attention, although make sure that the fault is not due to oil leakage or over filling.

4 If the engine is making obvious knocking or rumbling noises, the connecting rod and/or main bearings are probably the cause.

5 Loss of power, rough running, excessive valve train noise and high fuel consumption also point to the need for urgent attention, especially if they are all present at the same time. If a complete tune-up does not remedy the situation, major mechanical work is the only solution.

6 An engine overhaul involves restoring worn internal parts to the specifications of a new engine. The piston rings and main and


2»6 Engine, clutch and transmission



5.8a Detach the hose from the valve cover...

connecting rod bearings are usually renewed and the cylinder walls honed during a major overhaul. Valve seats are re-ground, since they are usually in less than perfect condition at this point, and valve springs and camchain renewed. The end result should be a like-new engine that will give as many trouble-free miles as the original.

7 Before beginning the engine overhaul, read through the related procedures to familiarise yourself with the scope and requirements of the job. Overhauling an engine is not all that difficult, but it is time consuming. Plan on the motorcycle being tied up for a minimum of two weeks. Check on the availability of parts and gaskets and make sure that any necessary special tools, equipment and materials are obtained in advance.

8 Most work can be done with typical workshop hand tools, although precision measuring tools are required for inspecting parts to determine if they must be renewed. Often a dealer will handle the inspection of parts and offer advice concerning reconditioning and renewal. As a general rule, time is the primary cost of an overhaul so it does not pay to install worn or substandard parts.

9 As a final note, to ensure maximum life and minimum trouble from a rebuilt engine, everything must be assembled with care in a clean and organised environment.



5 Engine -

removal and installation |w

Caution: The engine is very heavy. Engine removal and installation should be carried out with the aid of at least one assistant; personal injury or damage could occur if the engine falls or is dropped. An hydraulic or mechanical floor jack should be used to support and lower or raise the engine if possible.

Removal

1 If the engine is dirty, particularly around the cylinder head and sump, wash and degrease it thoroughly before starting any major dismantling work. This will make the job much



Date: 2016-01-14; view: 804


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