engine rebuild

what do i need to look for when i take apart my engine. what to replace and what to check out. i have to split the cases to get to the starter clutches fixed.

 

Id check seals, Check bearings id replace all that stuff no matter what just because why would you want to crack it open again for a bad bearing or seal. Replace as much as you can afford.

 

Just look every thing over real close. Miroscope if need be (Just Kidding). I go by this rule. If it looks bad replace it. Its too much of a job to do twice.

 

Replace all rubber items and seals.

 

i always looked for that 10mm socket... sorry couldn't resist
behind the universal flange you'll find some pinion shaft shims, mark 'em and put them back the same way
i ordered springs pins and rollers then found out the clutch was cracked and ordered the whole clutch that came with all that stuff, just something to keep in mind
theres some torx screws in there that are peened in and a real bear to get out.... impact driver

 

Don't forget to replace the starter chain guide and the starter clutch springs.

 

that is the reason why i have to tear apart the motor because of the starter clutch. i just hope we can put her back together right when were done.

 

I don't see why you shouldn't be able to put her back together again. You have the desire, a manual (I'm guessing on this but you seem intelligent enough), and this forum. What's to worry about?

 

Starter chain guide and starter clutch are the big ones I always hear about. If you do tear it all apart, don't forget the wear and tear items, like O-rings, piston rings, and any other parts listed above. New gaskets, new head nuts too I believe. Man, it sucks.. Then again, tearing my engine apart has been a fun headache.

Putting everything back together's been a breeze so far.

 

Robert Posted: Wed Apr 22, 2009 4:18 pm Post subject: Re: engine rebuild
I don't see why you shouldn't be able to put her back together again. You have the desire, a manual (I'm guessing on this but you seem intelligent enough), and this forum. What's to worry about?

i do have a manual i do have the desire and i like to think im intelligent on some level of these machines. i am going to do the new o rings and gasket kit and all of the other wearing parts. in a gasket set do i get the crank case gaskets to or do i have to order them separtly?

 

I am not rebuilding my engine but I am trying to strip the frame. I have everything off except for the forks/front wheel and the motor. The motor is totally kicking my butt. Any recommendations for getting the darn thing out of the frame? And who decided to put that stupid air box in such a place at to make it impossible to get out?

 

I tried the way it says to do it in the manual...not so much. And they made it look so easy.....

 

Rotax, they all have to be ordered separately (I WISH someone would kit them together). Give our beloved parts guru Chacal a call, he'll hook you up correctly and quickly (at very reasonable prices to boot).

 

alec- ive replaced my engine last year and though they say not to pry at all on the engine that is what i did and got it out. you need atleast another person to help get it out of its home. just be carefull of were you are prying. can i order a gasket kit and get just the crank case gaskets?

 

hi guys i noticed im missing the cam chain tunnel seal out of my xj650(only bought recently as a project) when i tore i down, here in Ireland that seal will cost me €80 thats $102, but i found an on-line company in the UK called WEMOTO will do a full engine gasket kit for the XJ for £65(sterling) which includes the cam chain tunnel seal, iv bought bits & peices for my xj off them & they r a good easy company to deal wit.h, check em out.

 

I ended up using a ratcheting tie-down strap to pull the engine up, wrapping it around the top of the frame, bottom of the engine, and tightening. Doing that freed it from the lower engine mounts. After that, I'd push it to the side, loosen the strap a bit, push some more, loosen, push, loosen. I was able to get it out of the frame by myself.

 

just lean over the bike looking forward from the right side of the bike. With your right hand, grab the nearest valve cover bridge to lift with. With your left hand, grab the bottom of the motor just behind and below the shift lever. I succeeded by rocking the bottom of the motor forward a bit first and then just lifting at both points and working it towards yourself and out of the frame. Be careful when you set it down, it naturally wants to rock forward pretty hard....my big toe got bit by the front mount ear.

 

Viper,

Did you try laying it on its side? I have seen that recommendation from some of the vets on here.