Engine swaps 101

[Dam_buster]

well. as said in another thread my head gasket went a few weeks ago, resulting in no compression, oil/water mixed and a angry Dammy!

instead of rebuilding the engine straight away i thought i would save myself some time, get a 2nd hand engine, put it in, and repair mine and give it a big ol overhaul.

well i shot down to Portsmouth this morning and collected a engine from a decent lad down there, seemed to know alot about zxr4's and races them.

was back home by 4.30, had a spot of lunch, and lazed till bout 7. started work on the bike, Binge came down gave a hand, and by 2 oclock this morning had the new engine in, and ready to go,

gonna sort the teething probs in the morning. as it would be taking the royal Pi$$ starting it tonight.

anyway here are some pics,

the tub full of crap is the oil i pulled out of my old engine.!!!
https://i4.photobucket.com/albums/y146/Dam_buster/DSC00186.jpg

old engine out.
https://i4.photobucket.com/albums/y146/Dam_buster/DSC00194.jpg

Flinstones motorcycle?
https://i4.photobucket.com/albums/y146/Dam_buster/DSC00203.jpg

managed to remove the engine also without having to split the chain, which was a plus.
https://i4.photobucket.com/albums/y146/Dam_buster/DSC00198.jpg

engine out
https://i4.photobucket.com/albums/y146/Dam_buster/DSC00201.jpg

Engine in
https://i4.photobucket.com/albums/y146/Dam_buster/DSC00190.jpg

mostly rebuilt and practically finished, all i have to do is fit the side panels!
https://i4.photobucket.com/albums/y146/Dam_buster/DSC00216.jpg

so yea, 8 hours and a complete engine swap later,

Dammy, Binge and gaz are fooking knackered.

hopefully all runs well and be good for the ride out 2moz!

im sure Binge will add to this later.

but as it is. its 4:12 and im still awake night people

JIM
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Yamaha R6 5EB, BMW 328i Touring, BMW 328i Coupe

[DaveH]

Good effort!!

A duvet!!??
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https://www.timhastingsracing.co.uk/

ZX7R & ER6F

[Dam_buster]

for kneeling and catching the engine, as not to scratch the casings when moving it about.

hehe absolutely cream crackered now tho!
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Yamaha R6 5EB, BMW 328i Touring, BMW 328i Coupe

[binge]

I was just impressed on how easy it was to change the engine over. The initial removing engine/fitting engine took what, 20 minutes?

Was just all the fairings, headers, Rad, Cooler, Pipe work and loom which took time.


Oh and the fact that all 3 of us were tugging away at the engine,

Jim - "Hmm, Im pretty sure that engine mount counts as two as it passes right through"

Ben - "hmm"

Pull pull pull!...

Gaz - "Nope, theres another one there".



Alls good though, Shame about the oil leak.
Hurry up and get it sorted, you got an hour.


See you in a bit.
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[quacker_boy]

Stupid question but...does it start?
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wizzzard wrote: Imagine God just stopping by, tidying your front room up and then quietly letting himself out again. Statisticly more likely to happen than Korn being on here.

[Dam_buster]

it does now!


wooot
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Yamaha R6 5EB, BMW 328i Touring, BMW 328i Coupe

[Dam_buster]

it doesn't now LOL
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Yamaha R6 5EB, BMW 328i Touring, BMW 328i Coupe

[binge]

Have you gotten onto the guy about the engine yet?
something seriously not right.

Symptoms -
Instantly over heating yet rad is full.

Any ideas anyone?

Please excuse my rather naked looking NC29, The fairings have all been sent away for spraying up.

https://bikechatforums.com/download.php?id=51607
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- Honda XL125S - CBR400 NC29 - VFR400 NC30 - CBR400 NC29 - TL1000R - TeeZeR Pit! - Bandit 12 - YZF450 - LuckyMX125 Pit! - Demon X XLR 140 Pit!
- Stomp KZ 160 Pit! - Demon X D-link 140 Pit! - CRF50F Mini-Pit - MonsterMoto 155cc MiniSM - Honda Chaly 150cc - Yamaha 98' R1
- Honda Chaly 140cc - Thumpstar 190cc 4v MiniSM - Aprilia RS125 Pit-Bike -

[Wafer_Thin_Ham]

Stuck thermostat?

Stuck closed, so the cooling system never opens to allow the water to flow.

Get it out and put it in hot water to see if it's working.
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[Dam_buster]

will do buddy, where abouts is it located? just under the carburettors isn't it?
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Yamaha R6 5EB, BMW 328i Touring, BMW 328i Coupe

[Dam_buster]

well pushed the thing 3 miles home lol, got some nods and a few bikers talking to me.

a group of girls in a ka stopped and asked what was wrong and if i wanted a lift. which was nice. said they'd be at the pub up the road from me, and that i should go up there later., so might take a stroll on up.

now im back at home. feel like i have popeye arms, and now have to start working on the bike again.

no big deal.

but the bike will be getting a full overhaul over the darker 6 months of the year

jim
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Yamaha R6 5EB, BMW 328i Touring, BMW 328i Coupe

[Zen Dog]

Could just be an airlock, did you squeeze all the rad pipework and rock the bike from side to side thoroughly?

Zen Dog
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Current - '94 VFR750FR, '00 VFR800FI Previous - '10 Street Triple R, '92 MZ ETZ301, '05 TTR250, NSR125R, KMX125, "Honda" Win (chinese copy of an old Honda design with a C90 engine)
My bike trip around S.E. Asia 2010/2011

[Dam_buster]

would an air lock cause the bike temp to go right into the red?
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Yamaha R6 5EB, BMW 328i Touring, BMW 328i Coupe

[DaveH]

Did it go into the red in three miles?!!!

Are all the connections done up correctly?

Can you tell if any of the water hoses are getting warm, or if the engine itself is hot to the touch?

How is the oil...you did put some in yes...
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https://www.timhastingsracing.co.uk/

ZX7R & ER6F

[binge]

It was in the read about 200 yards from where we set off but thats because the rad wasnt full. After filling it up at the petrol station it ran for a fair few miles, Then when we went to overtake Jim pulled out and his bike died, I was charging at him from behind at like 60+ and had to double overtake or id of gone into the back of his bike. Just lots loads of power and wouldn't rev right out.

Then it cut out and was very hot, But when the rad cap was removed it was full.

So either water pump isn't working?
Thermostat stuck closed (Sounds likely)
Or Worst case another fucked head gasket and water system is instantly pressurizing and getting too hot. (Hopefully not)


Plenty of oil and water in it anyway.
____________________
- Honda XL125S - CBR400 NC29 - VFR400 NC30 - CBR400 NC29 - TL1000R - TeeZeR Pit! - Bandit 12 - YZF450 - LuckyMX125 Pit! - Demon X XLR 140 Pit!
- Stomp KZ 160 Pit! - Demon X D-link 140 Pit! - CRF50F Mini-Pit - MonsterMoto 155cc MiniSM - Honda Chaly 150cc - Yamaha 98' R1
- Honda Chaly 140cc - Thumpstar 190cc 4v MiniSM - Aprilia RS125 Pit-Bike -

[Wafer_Thin_Ham]

[Zen Dog]

[Dam_buster]

the first one like binge said happened cos all the water was taken through the system, was then filled and went on our merry way.

must be an airlock of some sort, will take a look at both of my engines water pumps and thermostats


and use the best items.


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Yamaha R6 5EB, BMW 328i Touring, BMW 328i Coupe

[The Tot]

That was going to be a good little ride out till that event! Sorry i wasn't of much help then - i can only suggest little things like reverting back to the flintstones frame
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[Dam_buster]

i'll get it sorted.
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Yamaha R6 5EB, BMW 328i Touring, BMW 328i Coupe

[quacker_boy]

Ben you know how flush out a cooling system properly don't you mate?

Drain the old shite, fill up again with new coolant. Start engine to circulate coolant and then top up again?

Sorry if this sounds patronising but i'm just wondering if you did that?

All the reasons you've listed are probabilities by the sounds of the symptoms you've given. Fingers crossed for you it's not the headgasket mate. Good luck with it.

Chris
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wizzzard wrote: Imagine God just stopping by, tidying your front room up and then quietly letting himself out again. Statisticly more likely to happen than Korn being on here.

[Dam_buster]

its jim

aha (Y)

yea man will be going through everything, been working on the bike today need to get a few seals,

swapped the water pump over as the old one was rusty and shagged.

just waiting on a few last bits then i can start testing again

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Yamaha R6 5EB, BMW 328i Touring, BMW 328i Coupe

[quacker_boy]

I know you're Jim mate, i was addressing Ben cuz he seemed to know what was wrong and he's also a car mechanic isn't he?

So i was just checking he'd done everythin right. Change the seals that are knackered and then fire her up again.

Again, good luck boys
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wizzzard wrote: Imagine God just stopping by, tidying your front room up and then quietly letting himself out again. Statisticly more likely to happen than Korn being on here.

[Dam_buster]

bens a cowboy lol! yea were both car mechanics lol

gotta change those seals and fire her up, i looked at the other thermostat housing (the old one) and looked at the temp sender, and they were all fluffed up to the max, just covered in white build up. so have swapped everything over from the old engine,

so hopefully it'll be a winner.

JIM
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Yamaha R6 5EB, BMW 328i Touring, BMW 328i Coupe

[quacker_boy]

I'll stop digging myself a hole now then!
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wizzzard wrote: Imagine God just stopping by, tidying your front room up and then quietly letting himself out again. Statisticly more likely to happen than Korn being on here.