Installation times/duration?

junk301 · May 16, 2013, 06:15:35 PM

For a motorcycle mechanic. How difficult/time consuming is it to install the stator, rotor and starter into a drained engine?

GI JOE · May 16, 2013, 07:31:54 PM

I've seen I done on quads and stuff and didn't seem too long or hard but these bikes could be different. I don't see why it would be too much harder for a simpler bike. But don't take my word for it since I'm still learning, just putting my thoughts out.

adidasguy · May 16, 2013, 09:38:42 PM

Take off left cover: 5 minutes.
Starter: remove old and install new: 10 minutes tops.
Stator: Remove and install 10 minutes tops
Rotor: I'd allow 20 minutes only because removing the old one can be tricky and when installing the new one, the shaft and rotor must be spotless with no oil residue so the press fit will take hold.
Close up: Another 10 minutes.
Allow some time to remove old gasket and clean things.

So I'd say 1 hour to 2 hours labor. That's also based on me having done these things and I'm not as experiences as a trained mechanic.

Janx101 · May 16, 2013, 11:27:09 PM

Quote from: adidasguy on May 16, 2013, 09:38:42 PM
So I'd say 1 hour to 2 hours labor. That's also based on me having done these things and I'm not as experiences as a trained mechanic.

... reckon thats fair.... but also... Addy you are familiar with your bikes right through.... and yes most bike bits tend to go roughly in the same spots.... and yes a good mechanic with all the workshop and tools should know all the bits and bobs , as well as the theory/practical experience...

.. and JUNK301... are you asking ahead of a repair?... or trying to argue a bill after the fact? ... if its after then good luck bro!!

what about apprentices though?.... we have a 4wd repair shop next to the depot here... and some of the apprentices ...

... they know the basic theory .. but holy crap do they mess around while trying to figure out some things...

eg .. just before xmas an apprentice had done a snorkel fitting and fuel pump upgrade/cleanup to a diesel 4wd ... but he hadnt remembered to re-connect a plug to an airflow sensor.... the boss there took a look and spotted it, but as a training exercise said to the young bloke... "ok, you need to recheck your work and correct it" ... i happened to be wandering past about then and glanced into the engine bay while overhearing the chatter ... saw the plug loose and went to speak but the boss waved me off with a grin.. 2.5 hours later the young apprentice was just about finished checking every bolt, washer, spacer, ring clamp, fuel line etc ... boss wandered past and tried the key ... still no go... then asked the apprentice if he had actual stopped and looked anything over before he started checking... then reached in and popped the plug into its socket... tried the key and VOILA!! ... combustion magic!!... (also the customer was not charged extra for the 'diagnosis time')..

thing is... familiarity with a particular unit is sometimes just as valuable as mechanical 'training' ... if a greenish apprentice or even a fresh mechanic has been trained on say... BMW boxer motors or 2 smokers or even just all near new water cooled 250 hondas... seeing a GS500 might ... yes .. 'might' be a new thing to them.. often (unless its approaching ridiculous levels of time) the boss will just bill the hours it took a 'greenhorn' to sort out a problem... they wont admit their employee is a monkey on a typewriter ... it'll just be 'thats the time it took' ..

while all the advice on here (well most of it .. unless it us Aussies

) is based on practical experience and familiarity .. some of you tech heads i can just picture closing your eyes and thinking for 10 seconds.. then 'bluuuuurg' its all down on the screen .. which is great!!! ..

"what my friends on the internet said" .. is not a valid arguing point with a wrenchmonkey boss in a workshop! ..

just sayin!!

junk301 · May 17, 2013, 12:18:53 PM

This is pre-repair. Im also not arguing it I just wanted to let my mechanic know if there are unforeseen difficulties surrounding a gs500 (backyard mechanic). I bought an engine that didn't come with any of the electricals (stator, rotor, starter). Im just hoping that taking off my original engine and installing it in the new one, won't be that big of a hassle.

Thanks for listening and offering the great info!

adidasguy · May 17, 2013, 12:35:32 PM

I wonder about that. If the engine already had the rotor, stator and other stuff stripped from it.....hmmmmmmm..... well...... usually you do that to a junk engine. Do you know the engine missing parts is any good? Or the reason it was stripped of these parts?

junk301 · May 17, 2013, 12:38:33 PM

the place just said that they remove all the electricals from the engine before selling it. just another way to make money i guess..engine has 3k on it.

adidasguy · May 17, 2013, 02:06:26 PM

I guess since it is Canadian, we can expect some odd things to be done while having beers and back bacon. Eh?

Hopefully you manually cranked the engine with a wrench on the timing rotor to be sure it was not locked up or they guaranteed it was not locked. (19mm wrench on timing rotor, turn clockwise only to see if engine turns)

junk301 · May 17, 2013, 02:30:45 PM

they did guarantee it, however can i hand crank it with no oil in there? probably not. They drained the engine. There are some greedy bastards up here in canada. It's not normal its just that you cant find gs500 engines in canada very often.

adidasguy · May 17, 2013, 02:42:11 PM

There's enough residual oil that you can crank it around once with no issues.
If the timing rotor is off, then go ahead and put on the pickup and timing rotor. Do not over tighten the timing rotor bolt. It is long. Some have twisted it in two. Use a little threadlock unless you plan to take of the right side cover for some reason.

junk301 · May 17, 2013, 03:43:08 PM

No problem. Not locked! excellent

adidasguy · May 17, 2013, 05:14:18 PM

I think that is a relief to us all.

junk301 · May 18, 2013, 10:35:15 AM

going back to the flywheel. I don't have a flywheel puller. Is there another way I can pull the flywheel without the puller? and without destroying anything :p if I need the puller would buying a flywheel be easier. one on eBay for 18$.

junk301 · May 18, 2013, 11:02:29 AM

Quote from: junk301 on May 18, 2013, 10:35:15 AM
going back to the flywheel. I don't have a flywheel puller. Is there another way I can pull the flywheel without the puller? and without destroying anything :p if I need the puller would buying a flywheel be easier. one on eBay for 18$.

The Buddha · May 19, 2013, 08:47:40 PM

You dont need a flywheel puller. You need a sliding hammer with the right thread.
I made one - some type of 40lb steel donut welded up to a monster set of handles. It made mince meat of all rotors it looked at. Somehow I sent to someone on this site and it vanished.

You need a front axle - I think the GS front axle is the right size and thread, if not, a vulcan 750 is for sure, then you need a mondo heavy steel hunk with an axle sized hole in it.

Cool.
Buddha.

bryan88 · May 22, 2013, 12:39:26 AM

Quote from: adidasguy on May 17, 2013, 12:35:32 PM
I wonder about that. If the engine already had the rotor, stator and other stuff stripped from it.....hmmmmmmm..... well...... usually you do that to a junk engine. Do you know the engine missing parts is any good? Or the reason it was stripped of these parts?

It could have been a Police or some other kind of fleet bike. If those things sit in the workshop for more than 10 mins, people start robbing bits off them.

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Installation times/duration?