Engine Removal?

Can anyone point me in the right direction?

I'm looking for the post on removing the engine by laying the frame on it's side. I've tried the search function to no avail.

I'll be doing this myself so the lifting the frame off the engine should be the easiest. Do I need a wooden support system to lay it on, or just lay it on a carpet the pull the frame?

carpet? laying it down? removing the engine is simple. do you have a manual?

tank off, remove clutch and carb lines. undo motor mount bolts and ureeka.

kz1k wrote:

carpet? laying it down? removing the engine is simple. do you have a manual?

tank off, remove clutch and carb lines. undo motor mount bolts and ureeka.

You just reach in there and lift it out? :huh:

I've had best luck lifting the frame off. The covers are pretty robust, but carpet and some blocks to balance would be a good idea.

I would try it with a piece of cardboard or carpet on a car tire. Loosen the mounting nuts and lay it down. Once it's down pull the mounting bolts out and slide the frame off. This should be a lot easier on a welterweight 2 stroke!

"carpet? laying it down? removing the engine is simple. do you have a manual?

tank off, remove clutch and carb lines. undo motor mount bolts and ureeka."

Dude when I need someone to point out the cam or the crank I'll ask for your help! :woohoo: :laugh:

I know some one had a good one man method of engine removal and it is not covered in the manual. The method in the manual is a 2 man job with the frame upright.

I remember the thread your talking about. I did the same thing to pull my motor. Way easier when your buy your self. Make sure to support your motor only when its on its side. I used 2x6's and carpet and just built a frame, loosen the mounts lay it on the right side (has the removable mount) after on the side you can remove all the bolts and lift the frame right off... much lighter than the motor and do able by your self.

The frame lifts off the left [alternator side] because of the bottom motor mount that's welded to the frame on the left side.

Carbs off....exhaust off. Driver pegs off. Shifter off. Kick Starter off.

Get all your cable and electrical connections,etc. unhooked.


Get all the motor mounts unbolted except the bottom left with the teardrop nut. Leave the long front bolt in also but remove the tri shaped bracket, nut, etc.

Lay bike right side. Pull the long mount bolt out.

Remove bottom left mount bolt with teardrop nut.

Lift the frame off.

It's cake.... Even easier if you have the wheels and handlebars off.

what are u gonna do?? if u e doin motor work do some of the disassembly in the frame. that makes it much lighter and easier to lift out

kzrider.com/index.php?option=com_kunena&...d=2&id=322194#322194

hope this works

larrycavan wrote:

The frame lifts off the left [alternator side] because of the bottom motor mount that's welded to the frame on the left side.

Carbs off....exhaust off. Driver pegs off. Shifter off. Kick Starter off.

Get all your cable and electrical connections,etc. unhooked.


Get all the motor mounts unbolted except the bottom left with the teardrop nut. Leave the long front bolt in also but remove the tri shaped bracket, nut, etc.

Lay bike right side. Pull the long mount bolt out.

Remove bottom left mount bolt with teardrop nut.

Lift the frame off.

It's cake.... Even easier if you have the wheels and handlebars off.

One thing I might add, Oil out! If you tip the bike over with the oil in it will surly be all over the floor,frame and motor before you are finished!

I will also add if you are painting the frame it is also much smoother to remove the valve cover for an extra inch or so in wiggle room. Not as important on the way off as the way on.


Pfaelzer's link is the one I remember that was super helpful. I wish I would have done this years ago I have always called a hefty friend

Thanks guys!!!

Very helpful. Here's a couple of pics from the provided link for the next guy.





As for the plan on this one, the engine is a runner so it'll just get a paint job and polished covers. The frame will be blasted and painted and then the rebuild starts. Forks need new tubes and I'll give it the Race Tech treatment with springs and emulators, rebuild the wheels, the seat has already done. Thanks again Rob! I'm thinking on buying the repo bodywork, I'll also need pretty much every rubber part on the bike. The great thing about these bikes is most everything is available!

Once I get into it a bit more I'll start a new thread in the projects section.