motor extraction/insertion

I did my Kz1000 a1 last week, and after struggling w/removal finally broke down & decihered the removal/installation procedure in the manual. and w/minor changes,install was clean & took about a minute. Changes were, remove oil filter and valve covers,and exhaust studs. It takes 2 men, some way of locating rolling chassis uprite and stable, and a couple of lady bars small enough to fit into engine mount holes. Engine goes in & out r/h side w/entrance /exit initiated w/engine slightly forward, and r/h side slightly elevated. I like to put a couple layers of duct tape over lower frame rail as one needs rest engine there while walking around to l/side of bike to finish positioning. the key is in elevating r/side,lowering L to clear cam works at backbone. hope this helps. G

forwarded from a letter i sent a kzr member on this subject last week.....the kick starter to pull on for the helper is the shit.....my girl and i pulled a motor in two minutes lifting time...bike had a rear flat so that helped....and she has NO bike knowledge so that helped(she just did what i asked and did not fight me by lifting up too hard....

hey i saw your answer about taking the motor out yourself... i took a z-1 out a few weeks back and i left the kickstarter on and my girl with a glove on her hand helped pull up on the kickstarter as i did the lifting out in small stages ...we got it balanced on the frames left cradle and i came around the bike and she was all into helping ..she really just steered the wheight from the kickstarter as i lifted it to a stand on the ground...i know you know all this...i just thought it was really easy for her and she said it was'nt even heavy...i was gonna do it myself too..so as not to yell at her if it started tipping and start a fight...but together it was a breeze...the third hand helped tons ....good luck

I leave off as much as I can and wrap the frame with bubble wrap. I use a floor jack and a phone book and lower it in/

Can i leave the jugs off of my z1 900 when i put the motor back in? Can i fit the jugs on while the motor is in the frame?

nasty

oldkaws4ever wrote:

Can i leave the jugs off of my z1 900 when i put the motor back in? Can i fit the jugs on while the motor is in the frame?

yep

I always build the bottom end and put that into the frame. Much easier. You can install the cyclinders and head on in the frame.

Thanks plummen and arai60, that will save me lots of frustration when i put the motor back in.

At the very least , remove the valve cover and exhaust studs.Wrap the lower right frame rail from the bottom mount to the forward mount with ruber strips 2" wide. i cut ruber strips about 2"x 4" and tape them to the frame with electrical tape.Small peices are easier to get inbetween the frame rail and motor.
I lift the motor out with a helper and rest(balance) it onto the right side lower rail. Then walk around to that side so both of us can finish the removal from the rt side.
I tried pluming pipe foam once but the motor cut throgh it and chipped my new paint.With powder coat u may get away with less than the 1/16" thick ruber i used.
I took mine out again yesterday. since i am taking it apart anyways i removed the head, cyl,and pistons first.

i just did my 440 which is smaller but a floor jack under neath the bike with a flat piece of wood and then tape the frame in blue painters tape and then get a friend to help you get the engine into the frame

i helped mark1122 remove his engine the day before. that had to be the easiest removal i've done. and i've done more then i care to remember. someone earlier said to wrap the frame in old tire tubes. that might be the only thing i might add to my list of tricks for removal. i've never had any luck with placing the frame over the engine. last couple that i've done at home in the shop i used a chain hoist on a dolly.

pict of engine on table after removal with chain dolly

Hey Steve,What's cookin? Get to work. lol.:laugh: