Tip for engine removal / replacement and other tips

[tedmagnum]

After doing a major overhaul of an africa twin, i thought id post some tips and things iv found to help people avoid problems i had.

1) If you going to have to remove the Alt Rotor or Clutch for your job eg. Cam chains replacement, Remove the Rotor holding bolt and clutch nut BEFORE removing the engine from the frame or before any top-end strip down. These things are VERY tight and usually require an Airgun. A rotor strap and breaker bar didn't help me much.

2) If removing / replacing the engine from the frame. This is MUCH easier when the rear head removed. I rebuilt the engine fully and 3 of us (2 trained mechanics) couldn't get it back in without the rear head off. placing a trolly jack under the engine to balance it helps allot. Tape up your frame in old towels to prevent from certain scratching.

3)Clean off ALL the gunk and crap before you take things apart. Its usually easier and you don't need to worry about dropping gloop into your engine.

4)Find out what tools/equipment/spares you need BEFORE you start the job. having your bike off the road whilst waiting 3 weeks for an O-ring/gasket etc is frustrating.

3) If you remove the water pump housing, make sure you put the short bolt back into the lower right hole. If you don't, you wont be able to remove it again as the frame blocks removal with the longer bolt.

4)When removing key components, keep all the bolts, fasteners in little bags and tie them it to the component. When your bikes in 40000 pieces, remembering which bolt goes where is a headscratching nightmare.

5)When removing pipes/breathers/fuel lines etc, i always find it useful to colour code the ends with a selection of different coloured tapes or written labels etc. This way you know quickly and easily know which pipe goes where. When your bikes been scattered over you garage floor for 6 weeks, trust me when I say you wont remember


If i remember anything else, ill update this..

[DaveS]

Excellent Ted.
I'll make this a sticky as well.

[paultheold]

The engine is a lot easer to refit in the frame fully built if you place a trolly jack under the crank case, My hardest part was removing the motor from the frame.

[tedmagnum]

for me, getting the engine out was a doddle with the rear head off...

i did use a jack...it just wouldnt fit..

[africatijn]

Dave,
Isn't it possible to pour all this in a list type of shape. That way we don't have all the forum/post overhead.

Quite like the idea though of a how-to, and how-not-to list.

Cheers,
Tijn

[tedmagnum]

Dave,
Isn't it possible to pour all this in a list type of shape. That way we don't have all the forum/post overhead.

Quite like the idea though of a how-to, and how-not-to list.

Cheers,
Tijn

Definitely a good idea.. Maybe the Forum needs a section adding for a definitive list...

[paultheold]

If you read some of the previous posts within the forum, you will find that YEN_POWELL started a tips section, there were only three posts within the said section.

I am not having a go, but engine strips and builds has been well covered.

[DaveS]

All good points we need an easy way to do this.

Creating a list is ok but someone needs to trawl the site to find the tips and then combine then in to one!

I'll see if I can see any add-ons to the forum software that may help us.

[paultheold]

This one needs the thinking head on. One mans advice is another mans disaster.

I know how to work with metal, and mechanical things, but stumble when it comes to electrical components.

[tedmagnum]

If you read some of the previous posts within the forum, you will find that YEN_POWELL started a tips section, there were only three posts within the said section.

I am not having a go, but engine strips and builds has been well covered.

pauls probably right... Forums arnt a great place for lists and structure.. you need website hosted and updated by one person with a set structure.. This can be arranged easily though, I could build an africa twin website with a structures tip section for people to add comments too in the set section.. my only quarm would be, the effort involved would be too much as it would probably be forgotten about it 10 mins