TOPIC:

At what point it is best to install engine? Do I need help? What is the best way to do it to avoid scratches, etc. This is where I am at with chassis assembly:

 

No eBay APP ID and/or Cert ID defined in Kunena configurationI install the trans first into the frame and then the cylinders and head. I first have the rear and front wheels on and and supported with the center stand. I build a platform about 1/2inch taller than the lower frame tube. The engine sits on this. make it big enough so the engine is stable. The platform sits next to the frame. I then use my scissor jack  and slid it into the center of the frame to the same height as the platform. from there I can slide the engine over to the jack a little at time  watching the front and back. The engine will slide easy and will not hit the lower tubes. I do this by myself. To make it easy I place the engine on the jack first which sits pretty low. I then jack it up to the height of the platform and slid the engine onto the platform and over to the frame. take your time and you will not damage your paint or powder coat.

By the way I don't have the filter in at this time I do that later so the bottom is flat and slide easy.  

I start with a rolling chassis securely tied down to a lift. I don't want to try to place a motor in the frame with the chassis moving all over the place. I place rags over lower frame rails.
I have a completely assembled bottom end on the bench. When I am by myself I grab the dyno cover with one hand and with the other hand on the kickstarter. Then I lift the motor off the bench, then place the bottom end across the frame rails. With the bike up on a lift and the bottom end on top of the bench, I don't have to bend down with the bottom end to place it in the frame.
If you have the top end assembled on the motor it will take two people to place the motor in the frame!!!! Now that I am getting a little older (68 now) I like to have two people when I stick the bottom end into the frame. Been doing it this way since back around '72 or so!!!!! 

 

Thank you guys! In my case engine already assembled with a top end. I will put chassis on wheels, then protect frame with rubber (from old tubes) and have a helper.. Does that sound like a plan? I will need help anyways, assembled engine sits on my tall bench..

I think the manual has disassembly/reassembly with and without the engine in the frame.

With the 650 I installed the cases, including the oil pump and primary drive unit.  Then added everything else.  The engine is a tighter fit than a KZ1000.  I would recommend the tensioner before then the carbs.  Also, install the primary drive outer gear before doing the clutch. 

I kinda thought it may be all together. I would defiantly build a small stand and wiggle it in from there. My method should still work. You don't want to be trying to lift it in without support. It will be heavy even with two people. It will be top heavy now so you will need extra hands to keep it from tipping. Once you slide it in and if you have it on a jack you can gently lower it down to fit the bolts. Never done a 650 so it may be a little tighter but slightly lighter.

split  sections of heater hose and put on frame rails, then remove exhaust studs.

wrote:

split  sections of heater hose and put on frame rails, then remove exhaust studs.

Good stuff! Don't have exhaust studs yet. Will be no carbs and no exhaust studs

If I remember correctly, way back when.(in the 80's). I had my kz-1000A engine out of the frame 3 or 4 times. For placement into the frame I would place an inverted milk crate directly next to the frame and then position the rebuilt engine on the crate. I would Then straddle the frame and carefully inch the engine into place.( allready having a bottle jack or two in place under the frame. If done correctly you can float the engine within the frame for precise fitment. Good luck to you and safety first always.....

Main message received! Protect frame. Stabilize bike. Move engine next to the bike so it's positioned slightly above frame. Keep jack with platform inside frame. Carefully move in, then support with jack, position and tighten.

On several of the old Hondas that we have done we lay the complete motor on the appropriate side leveled out using wood blocks and carpet pad. Then we lay the bare frame protected with a bunch of tape and only the center stand installed down over the motor and install the motor mounts. Finally we stand it up on the center stand with a jackstand holding up the front. It is easy and less chance of scratching something.

I do the engine on its side for any bike where you need to assemble the engine first like my XS650 or the CB750. But any engine that can be assembled in pieces I prefer sliding it in with the majority of the bike assembled. Normally the engine is out for rework so I use the time they are out to assemble what I can. I may have three projects going at once and it sure saves a lot of room if the parts are on the frame and not scattered in the shop.