I think im gonna go balls deep in this seca.

So im waiting on an insurance settlement thats sopposed to go through eventually to fix up the bike. My plan was to get it running for now, then over the winter tear it all down and clean and paint everything. All with this money of course.

It's about 1/4 tore down waiting for some new parts to go in.

Well, its getting colder, and the money wont be here till december.

Im gunna pull the engine and everything thing else. take it down to the frame and work my way back up.

I guess what im going for here is damn near a full restoration.

Never gone this deep into a motorcycle. I have most the tools, the workspace for it, and plenty of time (When im laid off for the winter)

I have questions. First off, how exactly do you pulll an engine from a motorcycle.

Manual basically says remove mounting bolts and remove from right.... thanks haynes!

I do have a portable hoist, so im sure i could more or less support it, wiggle it out, and repeat.

Any tips?

I dont have many specific questions, im basically looking for general wisdom from guys who work on xjs, to a guy whos used to working on cars.

 

I've not tried it myself, but I've heard good results with putting some padding on the floor, laying the bike down on its right side, removing mounting blots, and then lifting the frame back up leaving the engine on the floor.

 

I loaned out my hoist so Ive been using a come along and roof beam in my shop. What I rigged up was some nylon webbing from an old set of ratchet tie downs, one for the front of the motor and one for the back.


like this:



You have to go around the frame the fist time to lift equal. I unbolted the motor, positioned the bike under the hoist, then lift the motor up, swing it slightly out from the frame and rest it partially on something. An old car ramp with a couple of 2x4's worked well for me. Then I reposition the straps under the center portion of the frame and lift again so I can hoist the motor the rest of the way out.

Ive swapped two motors around in 2 bikes twice this way and can have a motor out in just over an hour now.

(It may be possible to do it otherwise, but I found it easier to pull with the oil filter housing off)

 

If you are stripping the bike down, the frame is light enough to sit over the engine.

 

It's even easier with the 550, no real drivetrain to attend to once the chain is off; plus the motor is light enough that with a helper you can just "boost" it out of the bike.

The best "tip" I can give you is to get ahold of a complete "reference library" for the bike. You mentioned Haynes; to the best of my knowledge there is no Haynes book for the 550s.

Get a factory service manual, the Clymer book, and a dealer assembly manual for the bike; having all of the necessary info at your fingertips really helps. Dealer assembly manuals pop up on eBay frequently, and generally go for $10 or less.

Another good "tip" is those plastic throwaway food storage containers from the grocery store to store various parts and subassemblies in, with their hardware. The larger round bowls will hold a 550 clutch assembly with no problem. Along with those, a roll of masking tape and a couple of Sharpies (for tagging wires and parts) you can keep everything sorted for reassembly.

 

I think I'll be using your little method soon(ish)....

I'll be starting a new thread soon in regards to my broomstick and it's issues and (soon) mods.

 

The closer you can support the motor (on it's side) to the position it would be after it's installed, the easier it is...

skillet
btw hope that made sense...

 

Thanks guys.

I get the feeling ill be using the ratchet strap method to get it out, it seems like Itl be easier to manipulate the bike to get the rest of the parts off the frame.

On reassembly I might try setting the frame around the motor, depends on how I'm feeling at that point.

I had a friend with me over the weekend, and he was interested in helping me lift the motor out. Unfortunately as I started wrenching the few things left to get the motor out, we realized we were way too inebriated. All I have is the girlfriend for help, so I'm going to try and avoid any heavy lifting.

 

yeah I have a bad back due in part to a bike accident many years ago and any attempt to lift anything over about 30lbs sends me into spasm for a while. I use mechanical advantage whenever possible.

Ive not had my frame torn down far enough to try that lay it on the ground method. I like keeping my frame a rolling chassis as that makes for easy transport and storage.

 

Well, I've got the forks and triple tree to take off and the front'll be tore down. The swingarms all that's left on the back too. Just got wiring/cables, rear plastic, a few odds and ends and the motor will be all that's left.

It feels weird taking this thing apart. I feel like I'm ruining this awesome machine. I've never had the funds to completely fix something up before, this is a new experience to me in a couple ways. Strangely exciting, and depressing at the same time, lol.

I guess its been a good season though. I got to work on my first motorcycle, get it running decent to where I can ride it, and actually rode a motorcycle for the first time. All in a month really.

Anyway, thanks again guys, I'm sure ill have questions as this goes on.