One-person engine removal

Hi all,

I'm at the start of a frame-up restoration of my '73 750 and have gotten to the point where I need to remove the engine from the frame. I would like to see if I can manage to pull the engine as a unit, by myself. I have read about the lay-it-on-the-side method for pulling an engine and have a couple of questions concerning that technique.

a) What side is the easier of the two to manage? It appears that laying the machine on its' right side (protected from the garage floor, of course) would be the easiest. Has anyone ever removed an engine on that side?
b) What is the approximate weight of just the engine unit? I'd like an idea of what it is that I need to muscle after removal.
c) I have the transmission loose in the cradle but can't see a way to remove it yet. Does the entire cradle/swingarm/rear wheel assembly have to be removed to extract the transmission, or is there another way?

Thanks.

ColoCommando said:

Hi all,

I'm at the start of a frame-up restoration of my '73 750 and have gotten to the point where I need to remove the engine from the frame. I would like to see if I can manage to pull the engine as a unit, by myself. I have read about the lay-it-on-the-side method for pulling an engine and have a couple of questions concerning that technique.

a) What side is the easier of the two to manage? It appears that laying the machine on its' right side (protected from the garage floor, of course) would be the easiest. Has anyone ever removed an engine on that side?
b) What is the approximate weight of just the engine unit? I'd like an idea of what it is that I need to muscle after removal.
c) I have the transmission loose in the cradle but can't see a way to remove it yet. Does the entire cradle/swingarm/rear wheel assembly have to be removed to extract the transmission, or is there another way?

Thanks.

Click to expand...

a) I'm pretty sure you have to remove it from the right (timing) side due to the shape of stuff.
b) heavy. I can pick it up by myself. I think I've heard 150lbs.
c) engine has to be loose or out before you can remove the tranny.

All of the following require the primay system to be completely removed first:

If you remove the head, then the cylinders, then the pistons, you'll be down to the heaviest single lump being the power unit lower end. Once you remove all the rear bolts and the front iso mount bolt, it will easily work free and out without laying the bike on it''s side.

If you simply must, remove the top steady, remove front iso mount bolt, loosen the top rear engine mount bolt, remove the middle and lower rear mount bolts, tip the engine up and block it in place, then remove the tranny first.

If you are reasonably fit, wear a "kidney belt" (back support), and maneuver carefully, you can remove the power unit with the top end still installed by just removing the top steady, front iso bolt & 3 rear bolts, then working it free and out.

I don't know what "triggers" me to remove the top end before pulling the power unit out, but I seem to do it about half the time. I've done at least a half-dozen by myself, and another half dozen with a helper; now that I've been without a helper for almost a year, the last few have been solo. I'm reasonably fit, but occasionally suffer from a sore back after doing engine lifting (not always). Tylenol or Motrin and a good night's sleep, and I'm okay again.

The engine alone is pretty manageable for the average guy. The engine/trans/cradle as a unit can be done by one person, but not very easily and is awkward too boot. Better to have help in this case.

To remove the transmission in the bike you need to take out two of the three engine-to-cradle bolts and pivot the engine to clear the transmission. If you are pulling it anyway, I'd leave it in the cradle.

If you have removed the front forks, sheet metal, oil tank, rear wheel, swingarm, and rear fender, you can lay it over on the right side on a thick carpet or pad, remove the iso bolts and manuver the frame off the engine. Make sure you have completely drained the engine sump and transmission first or you will have big mess!

Thanks for the replies.

I had previously drained the oil, stripped off all of the sheet metal and removed pegs and pedals.

I laid the bike on its' right side on a padded surface, braced with a couple of 2x4s. The engine (power unit) came loose easily after removing the engine mounting bolts and, after struggling a bit, pulling the front and rear ISO bolt/shaft. The engine is sitting free, ready to move and rolling chassis is off to the side. I just have to figure out how to move the engine around until I transport it to the shop. I think a hand-truck might work.

Now to figure out how to get the transmission free from the engine cradle. But I'm pulling the rear wheel and swing arm off, so the problem may solve itself.

ColoCommando said:

Now to figure out how to get the transmission free from the engine cradle. But I'm pulling the rear wheel and swing arm off, so the problem may solve itself.

Click to expand...

Tranny comes out with some turning and twisting. But with the engine out it's no problem.