Engine Swap series....

[TeBo]

Ok, I just gone outside, starting on my engine swap.  So far, so smooth (for the most part.)  I'm on the taking my bike apart process....  So far, got the seat off, gas tank, air box, choke lever/accel/switches and carb.  SO MANY HOSES ! ! !  Anyways, I have a hose, comming out of the bottom of the airbox, that looks like it got melted by the muffler..  anyone know where this go??

Also, there are a few lines that go nowhere..  Like the line that goes from the middle of both carb inlets, which doesn't seem to go anywhere??  Also from the gas tank but I assume this is the overflow line..

Things I"ve leanred so far.

DIS DANG BIKE GOT A GRIP OF HOSEs n' WIRES! ! !
you need to YANK the airbox out.
That lil' bracket thing that holds the gas tank on, ISN"T A LATCH
bikes could possibly be messier to work on than cars (DANG CHAIN LUBE.)
Gas on an open wound stings like a muther..(cut myself w/ a screwdriver.. go figure.)
Carbs have a lot of hoses that go through them...  Know where they go!
the gas tank can be sealed, and left closed, w/ out draining it  
and THAT THIS SWAP WILL NOT BE POSSIBLE IF i DON'T GET A 2ND HAND!

anyways, here are a few questions that came up, while I was breaking my bike apart.
1)That hose that burned off.. anyone know wehre it goes?  (it's under the airbox.)
2)would it be smart to change the sprocket now that the engine is taken apart?
3)how do you take the clutch cable off??  It seems like I have to pry the little thing open w/ a flathead, but it woni't fit inside the gap....
4)There's a wire that goes through, by the clutch line and shifter..  wtf is it, and how do I get it off?  Or do I unplug it from the bike end, not the engine end??

Thanks I kno confusing, but help a kid out=) :mrgreen:  

[Blueknyt]

1)That hose that burned off.. anyone know wehre it goes? (it's under the airbox.)

this is a drain hose for acumulated oil from blowby, spose to exit bottom of bike almost looks like its pinched closed, its so water and debris cant work its way back upline.

2)would it be smart to change the sprocket now that the engine is taken apart?  

you can if you like doesnt matter in or out of frame

3)how do you take the clutch cable off?? It seems like I have to pry the little thing open w/ a flathead, but it woni't fit inside the gap....  why pull the cable from the coverside?

DQ it from the lever side and fish it out, or just let it hang off the bike if you gonna change the sproket anyway.

4)There's a wire that goes through, by the clutch line and shifter.. wtf is it, and how do I get it off? Or do I unplug it from the bike end, not the engine end??

there should be 2, one contains 3 wires from your stator for your charging system and the other is a single wire that is for your neutral light

unless you have to swap these to new motor, disconnect them from the harness, also disconnect the ignition wires that come from under right hand cover and use a tie wrap, or wire tie to bundle them ontop of starter.

care for a basic write up on engine R&R?

[Dom]

THAT THIS SWAP WILL NOT BE POSSIBLE IF i DON'T GET A 2ND HAND!:

You can do it...just ask us if you have questions.

1)That hose that burned off.. anyone know wehre it goes?  (it's under the airbox.)

It goes nowhere, just drape it back by the shock.  Same thing with the one that comes of the top T connection on the carbs.  I think same thing with the one from the bottom of the airbox too.  Sounds like you had a Cali model that they took all the emissions crap out of.

2)would it be smart to change the sprocket now that the engine is taken apart?

It only takes like 5 minutes to do.  Not any easier to do it now, unless you have the rear wheel off, that's what would make it easier.  But seriously, no need to rush out and buy a sprocket now...Soooo simple to do it later on.  It's easier to do than removing the tank....that's for sure.  Remove the side plate that covers the front sprocket and there is a circlip holding on the sprocket.  It's hard to remove without circlip removers though.  Might want to get yourself some.  I bought mine from the bargain bin at Autozone for $3.99.  Money well spent.

3)how do you take the clutch cable off??  It seems like I have to pry the little thing open w/ a flathead, but it woni't fit inside the gap....

Just remove the whole plate on the left side that you see the cable going into.  Leave it off until you swap the engines and put the old plate onto the new engine.

Were you talking about removing the clutch cable from the lever itself?  

4)There's a wire that goes through, by the clutch line and shifter..  wtf is it, and how do I get it off?  Or do I unplug it from the bike end, not the engine end??

:dunno:

[Dom]

Heh...guess you beat me to it, Blue...

[Blueknyt]

ok, going from the point of bike on centerstand or 2x4 tied across handlebars resting on tall Saw horses (not everyone has a chainfall in thier carport) you want the bike straight up and stable, (i also tie 2 concrete blocks to the front tire jsut for added hold from rolling.)

Baggies help alot keeping bolts, nuts,screws and other small stuff seperated and safe. cardboard box helps hold baggies  

DQ= Disconnect

remove the seat, set out of the way.
Battry removed and in safe place.

unbolt the fueltank, shutoff the fuel, DQ the 2 hoses and remove the tank and set on a old folded towel, out of the way, make sure its not leaking fuel.

remove the bolts for tankmount and loosen the clamps for the airbox (if equiped) remove airbox.

loosen the clamps holding the carbs to the engine, pop the carbs out of the engine(dont turn them upside down, gas will leak out) you may DQ the fuellines and cables if you like, label them with tape and take notes so your not guessing later. I let mine hang over the left side of theframe

on the left side of the bike,  remove shifter bolt, pull shifter put bolt back in shifter, remove the bolts for the shifter cover and put them in a baggie with the shifter

at this point i generaly pull the snap ring for the front sprocket and slide the sproket off the shaft, letting the chain hang on the swingarm, put the sproket and snap ring in the bag with the shifter cover bolts

pull the screws for the starter cover(baggie), unbolt the positive lead for starter, put the nut back on the starter.

follow the "wires" from the shifter cover area to the harness, DQ them at the plugs and drap them over the engine.you may lable them with tape if you like. DQ the Negitive battry cable where it connects to engine (mine is on the starter mount bolts by my choice)

look at the harness coming from ignition trigger behind small cover on right side of engine, follow it to harness and DQ the plug(label?), now take those other 2 wires from opposite side and bundle them all together so they dont fall all over while your moving the engine around later. tape,tiewrap, or string will work fine.  



remove the bolts holding the exhaust on, bag and box the bolts (put the gaskets in the bag too if they happen to come out)

DQ the coil wires going to spark plugs loop them into the frame, DQ the tachometer drive cable (tie it to a forkleg)

remove all the short bolts and nuts from the engine cradle "Breast Bone" as i call it, Bag em,  remove the long bolts and nuts from front and just below the engine, watch for the spacers there should be 2 long, and 2 short, 4 total. slide the spacers back on the bolts put the nuts on them.

You know should have the "breast Bone" laying on the ground, set it out of the way.  you should be on right side of the bike at this point

easyest way to handle the engine with only one person doing this is with a rolling floor jack, extra hands help, but hard to watch 4 hands all the time. placing the jack under the engine around the oil drain plug, perhaps just infront of it (tward front of bike) is about center of the weight, pump the jack up till it just touches the engine

remove the 2 remaining nuts on the bolts behind the engine, the engine might sag alittle in fram, might not. pump the jack again super slow till you see the engine shift alittle in the frame. pull the bolts out and slowly wiggle (or pry with screwdriver) the engine forward in the frame till it clears the rear mounts

(BE CAREFUL ITS HEAVY AND WILL HURT IF YOU PINCH ANYTHING BETWEEN FRAME AND ENGINE)

once past the rear mounts, slowly turn the back of the engine tward  the right side, you might have to shift the head around alittle to do this, ballence on the jack is very important.(extra hands help here but again, hard to keep track of) once the rear of the engine is out, slowly lower the jack in small amounts,( keeping one hand on the egine to keep it ballenced on the jack if working alone) slowly roll the jack/engine tward you away from frame.  watch your feet plz. lower the jack all the way down (SLOWLY) tip the egine over till it touches ground, and pull the jack out.

putting an engine back in is the reverse, its alittle more tricky getting back in the mounts so keep your helper around if you can. once you get the 2 rear bolts inplace you got it licked.

Key factor is taking your time, dont get in a rush.  if you get frustrated walk away for alittle bit. always stay safe.  the first time i assembled my GS, it took me over an hour to get the engine installed into the frame.

i dont think i forgot anything, my bike is setup alittle differnt then most so i dont have as many steps with mine.

right now im filterless, not even an airbox. need a lunchbox to be honnest.

[TeBo]

blue thanks for all the info! ! !

My whole swap is actually based on instructions you gave another guy on this board, and was linked to me by Kerry..  So all the help is appreciated.  
The throttle, throttle cable, Choke and all the other fun stuff just came in the mail today.  So all I say is IMma have sum fun later this afternoon tryin to fit this stuff on .  

It looks like all the wiring on the bars are hooked on, so I should have no problem hookin' it to the new engine.  We'll see how everything goes=).  I will be picking up the new engine tomorrow, so we'll have to see how it goes from there=)

[TeBo]

FUN New CHALLENGE ! ! !

I just found out, the wiring plugs from the 01 wiring cables, are different from the ones I havew. :x ...  oh well, here goes my theory....

When I looked at the old cables, it looks like they mostly run the same colored wires..  THing is, it seems like they just bundled up more stuff in one harness in the new wiring system.  I was wondering if I should just cut the old harness off, and splice it into my new wires.  Thing is, there are a few wires that I don't have in the old one.  Like the new Wiring harness throttle side, have 2 wires that seem to end up in the same place?  (Colored orange/blue, and Orange/yellow I think.)  the rest seems pretty straight forward.  Boy would I laugh if when I put my bike in neutral, I start to signal left :lol:  but we'll see.. thanks for all the help so far  

GAWD GEEZ I LUV FORUMS ! ! ! !

[Blueknyt]

you could grab a new stator cover gasket(9$) and just swap over your old stator keeping the same plug. the ignition trigger leads should be the same on all the gs500's, but they are easy enough to transplant too.  no problrm at all with splicing the nuetral light wire, have at it.

[TeBo]

so does anyone agree w/ me, not necessarily know. but:

is it ok to believe the same colored wires from teh pre '01's would match the wire colors for the 01+ wirings??

[Blueknyt]

why guess when you dont have to? use your old stuff, or look it up in the book

[TeBo]

hahah seems like someone up in the clouds don't want me to get my engine today!  BUT I DID ! ! !  So now I have the engine sitting in the garage, ready for swapping tomrrow.. (if rain isn't too hard.)   as an added SUPER BONUS:  It includes the WIRING HARNESS ! ! !  so now I can prolly just slap this harness on, and basically have a whole '01 setup, on a pre 01 chassis     so let's wait till tomorrow to see if I could actually get this stuff slapped on right :dunno:

[TeBo]

I HATE THIS RAIN ! ! !

[Blueknyt]

sitting in the garage

 Um, there is a word in there that seems to be Key, regaurdless of Outside weather. engine swap doesnt take much room to perform.   AND, if you dont finnish in one day, push the bike in tight to the wall, spare/old engine behind it pull the car back in.

[TeBo]

normally, sure..  Except that I live in a Condo, w/ a small closed garage, that right now houses an '88 BMW M3, w/ a Evo3 engine half way in.  Plus there are no lights in my garage.  So I have to pull my bike out to my outside parking spot to work on it.  It would normally be done in  a day, except for a few factors.  1)  It's friggin' raining the past how many days here.  2)I still need to borrow a Hydraulic jack (I don't think my lil' screw 'em up jack would work.)  3) it took me ever dry moment I've had to put in the new wiring harness ('01 harness is different from the old ones.)  and last 4), I tried lifting that engine by myself..  Dude..  It's heavy!  heheh.. I still need to find time when me and my best friend both have the day off. (Which woulda been yesterday if it wasn't pouring.)  

I just want to get this over with, but geez..  Feels like someone up in the clouds really don't want me riding=P :dunno:

But really tho, This swap proves to be a lil' more difficult than I thought.  Oh well, we'll see

[Blueknyt]

its a tad heavy true, i know i have to ready myself to put it on my bench above the waist.  remember to use your legs.

a little cheapy 20$ rolling floor jack is all i used, i think pep boys and Advance auto still sell em

[paternoster2012]

I took mine out in Nov

Hopefully Ill get it back together soon

[TeBo]

I think the engine out and in, might be the easy part.  I just need to get the wiring harness in properly.  I guess someone took out the wiring harness off my old wires, cuz there are some extensions that are just crimped, as opposed to having the connectors.  So now I have to splice the new wires to fit as well.  This is where it's been complicated so far.  I need to get everything in soon.

I just hate going into the garage, and lookin' at my bike, all in pieces.  But then again, I also need to find hte time and everything to finish.

[paternoster2012]

You hate when you go in the garage....
Mine is sitting in my bedroom in that pic

I cant wait till its all back together
Evere sicne I got this stupid GS for my lady Iv been neglecting my poor 6R

[TeBo]

hahah. gee..  Yea, other problem.. . .   I just got a Gixr600 as well, but instead of riding it on my free time, I'm workin' on the GS500 gettin'f rustrated.  Just something about that bike that I can't help but love.  Oh well. . .  Back to the garage

[TeBo]

WHOA YEA DOGGY ! !   hahah. finally got the old engine out, and did it with my WIND ME UP FLOOR JACK!  ! !  Since my jack didn't have wheels, I couldn't do the put it on the jack, pull it forward, turn it to the side, and pull it out....  It was more like Jack it up, grab hold tight, wiggle wiggle wiggle, pull the jack down, wiggle some more, and more, and more, and then twist it out=)..  :lol:  :dunno:   anyways, found a good way to get the old motor from my driveway to the garage too.  hahah..  take my old Razor scooter, and slide the old motor on top, sit on the motor, and push away! ! ! !  hard part down, HARDER PART TO GO! ! ! :x