RAC4IT
Needs a job
Bergie
Posts: 3009
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posted May 30, 2003 11:42 AM
Engine removal and disassembly (tips?)
Anyone have some good tips on engine removal and disassembly? "To Do's" or "Don't do!" would be appreciated.
I have two engines to pull out this weekend, disassemble, and send the cranks out for inspection. Both are likely bearing failures and I'm seeking your advice on what to watch out for... thanks!
  
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MadMike
Moderator
FEAR THE BLACK FLAG!!!!!!!!
Posts: 6579
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posted May 30, 2003 12:46 PM
 Edited By: MadMike on 2 Jun 2003 08:35
Way, way to busy now but give me a call and I can give you a few tips!! for sure,
Mad Mike
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200-MPH CLUB MEMBER!
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RAC4IT
Needs a job
Bergie
Posts: 3009
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posted May 30, 2003 09:15 PM
cool thanks i'll hit you up
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AnotherRedHead
Expert Class
Posts: 348
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posted May 31, 2003 06:34 AM
Dont lose any parts! Im the parts buying king because of all the stock crap I lose!
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ninjamissile
Expert Class
Posts: 222
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posted June 01, 2003 11:59 AM
I just pulled my old motor and stripped it down. It's a piece of cake. Just take your time and you will be fine. The Kawasaki service manual (part no.99924-1253-03) is a must though. The only special tools you need are a clutch puller part no.57001-1243 and a flywheel puller part no.57001-1405. The flywheel puller I borrowwd from a friend and I made my own clutch puller out of old clutch plates. Dont forget to mark and label everything so you now exactly how it goes back. Even take photo's if you have to.
Good luck
Ninja Missile
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RAC4IT
Needs a job
Bergie
Posts: 3009
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posted June 02, 2003 12:20 PM
how the hell do you guys support this thing? I've got it on a hoist but I don't see any good method of sitting it on a bench to work... hmmm
this sucks
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ninjamissile
Expert Class
Posts: 222
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posted June 02, 2003 12:23 PM
Edited By: ninjamissile on 2 Jun 2003 13:24
I placed mine on a strong bench and supported it with wooden blocks placed under the motor. No probs whatsoever.
Ninja Missile
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RAC4IT
Needs a job
Bergie
Posts: 3009
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posted June 02, 2003 12:52 PM
ok I'll have to figure something out then... right now it's hanging
http://berg.fbody.com/zx12r/060203/
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AnotherRedHead
Expert Class
Posts: 348
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posted June 02, 2003 02:38 PM
I take the TB off it and flip it over with the stock pan. with a coby pan it sits flat easy
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RAC4IT
Needs a job
Bergie
Posts: 3009
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posted June 02, 2003 04:45 PM
I'm sending two pans to Coby this week 
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MadMike
Moderator
FEAR THE BLACK FLAG!!!!!!!!
Posts: 6579
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posted June 03, 2003 04:40 AM
I just used a floor jack on the front of the oil pan, and lowered it . worked good for me.
MM
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200-MPH CLUB MEMBER!
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ninja12
Needs a job
Posts: 3310
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posted June 03, 2003 07:12 AM
anyone have pictures of the coby pan and price?
and the mad mike pan and price?
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kcadby
Pro
Posts: 1733
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posted June 03, 2003 10:43 AM
Edited By: kcadby on 3 Jun 2003 11:47
If you screw together 2-2X8s in a L-shape...THAT will sit under the oil pan and actually make a pretty nice engine stand for the 12s... 
It goes across the front and down one side of the oil pan...it sits under the heads of the oil pan bolts...
WORK-FER-ME!!!
I have R&R-ed 12 motors a few times now by myself...you just block up the motor and lift the chassis off the motor by the forks...
IT'S EASIER THAN IT SOUNDS!!!
I install them the same way...motor is blocked (on my L-shaped stand)...I lift the chassis over the motor by the forks then...tilt the motor forward to get the first (rear-lower) motor mount bolt in...
After that??? it's EASY to raise the motor to install the rest of the mounts
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RAC4IT
Needs a job
Bergie
Posts: 3009
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posted June 03, 2003 01:12 PM
thanks, yeah I've got it out and on the stand. Any tips on disassembly of the engine itself? What should I be looking for? Should I take a measurement of what the cams are degreed at before I tear it down? I don't recall what Lee had them set at..
The engine I'm working on right now is from the green bike, which lost ~50hp on the dyno, no catastophic failure just massive loss in power, oil analysis came back with high lead content, so I'm hoping I can just put new bearings in it..
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ra12r
Zone Head
Posts: 919
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posted June 03, 2003 03:28 PM
Rac4it, you are making me nervous with the questions you are asking vs. the serious nature of what you are doing. You need to seriously call someone and talk with them. Even if it is just a small engine repair guy! If you can afford oil analysis, then please just hire a local motor builder to do the work. If you are guessing and fudging and miss one thing, it could cost you a whole lot more!!! Just concerned that's all..............
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All must bow to the "Ra Supremecy"...
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RAC4IT
Needs a job
Bergie
Posts: 3009
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posted June 03, 2003 04:11 PM
LOL thanks
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krexken
Zone Head
Posts: 732
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posted June 04, 2003 07:53 PM
The only 12 I've witnessed a failure on was a friends that ate several bearings due to his suction strainer getting clogged with clutch debris. His suffered a bad case of hot lapping disease. He actually unplugged the oil sending unit at the track cause he got tired of looking at the red light staring him in the face. This same guy also exploded two stock clutch baskets before buying a billet one.
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kcadby
Pro
Posts: 1733
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posted June 05, 2003 12:17 PM
quote:
The only 12 I've witnessed a failure on was a friends that ate several bearings due to his suction strainer getting clogged with clutch debris. His suffered a bad case of hot lapping disease. He actually unplugged the oil sending unit at the track cause he got tired of looking at the red light staring him in the face. This same guy also exploded two stock clutch baskets before buying a billet one.
Sounds like that guy DESERVES to replace a motor...or 2...or 3?!?!?!
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RAC4IT
Needs a job
Bergie
Posts: 3009
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posted June 05, 2003 03:21 PM
Not good :-)
More here:
http://berg.fbody.com/zx12r/060503
Check out the surprise I found in the bottom of the pan in pic labeled "wtf"?
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zrxdean
Needs a job
Posts: 2225
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posted June 05, 2003 07:13 PM
Ewww. Kinda morbid, like a violent crime scene. Luckily, you can rebuild it - stronger, better, FASTER.... (for only 6 million dollars....) 
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TurboBlew
Moderator
BUSY DOING THE SCHIAVO
Posts: 4590
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posted June 06, 2003 02:51 AM
Sorry Dean...the $6,000,000 figure has been adjusted for inflation..... it will now cost $150,529,371.44
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Also a BadAss Internet Forum Moderator 4 Hire!! Come at me brah!
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kcadby
Pro
Posts: 1733
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posted June 06, 2003 07:37 AM
Nope...not good at ALL 
Bergie...I've been going just plain NUTS here since BEFORE BIKE WEEK...
I burned CDs and bought US-mail envelopes weeks ago and just haven't made it back to the post office (7-miles from my home) to mail them to you...
I've got some DL stuff (tickets) to take care of Monday but...I will try to get the CDs to you also...
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MadMike
Moderator
FEAR THE BLACK FLAG!!!!!!!!
Posts: 6579
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posted June 06, 2003 03:47 PM
Yep I have seen that before...
Mad Mike
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VincentHill
Needs a life
Posts: 6520
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posted June 07, 2003 12:00 PM
I will Bet #3 is in the worse shape! Plus it is on the right side of the pan!
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swft
Needs a life
Full throttle!
Posts: One MEEEEEELLION
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posted June 07, 2003 04:48 PM
That's what died on me, #3...
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