Engine change help needed!

Tupoar · Derestricted Danger Joined: 08 Jul 2011 Karma :

Good day to you all...

I'm currently in the process of removing the engine from my Yamaha SR 125. Closely following my Haynes manual every thing is done apart from emptying the oil via the sump and loosening the engine bolts. And this is where I'm stuck.

I have been hammering away with my impact screwdriver but the bolts aren't shifting. Before I completely round the bolt heads off can anyone suggest some good tips to loosen them up apart from wheeling it down to my friendly car garage and use their tools??

Thanks in advance

T

at106 · Brolly Dolly Joined: 16 Jul 2011 Karma :

If it's like my suzuki ts50x there are nuts on the end of the bolts? If there are try soaking them in wd40 or something similair, and make sure you have a GOOD fitting socket. If that doesnt work if you have a blow lamp or similair heat up the nuts and they should be easier to take off.

If none of the above work you could use a dremmel or hacksaw and cut the nuts down the middle and they should fall off, and are cheap to replace.

Vincent · Banned Joined: 16 Oct 2006 Karma :

Do you have any pics of the offending bolts?
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Space Is Deep

Tupoar · Derestricted Danger Joined: 08 Jul 2011 Karma :

@at106 - Yes they do. I will try you approach in the morn.

@Vincent -Nope but I can post some in the morning. But I can tell you it's the sump nut and every bolt/nut I've tried that holds the engine.

Cheers guys Smile

Nope. · World Chat Champion Joined: 16 Feb 2011 Karma :

Plusgas. Get some now.

Spray all the bolts down and wait 24 hours. Its a penetrant that should help loosen them up. You also want to tighten them slightly before you undo them. That should help get them out.

If your really in a bind you can also try heating the bolt with a blow torch and then as it cools down it will contract PERHAPS helping you release it.

One tip for when you put them back in, copper grease the bolts so they dont stick as bad as before.
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Former: Derbi GP1 50, Sachs XTC 125, Suzuki GSXR 400 GK73A, Kawasaki ZX7R, Suzuki DR250, Yamaha RD350
Current: 2011 Yamaha XT660Z Ténéré, 2003 Yamaha YZR-R1 5PW (In Build), 2009 Kawasaki ZZR1400

Tupoar · Derestricted Danger Joined: 08 Jul 2011 Karma :

Computid

I managed to get Halfords cheaper alternative of "Shock and Unlock". I have to say, I'm impressed. Engine is now on the kitchen floor. However....

I got a replacement engine off Ebay. It's in good condition. It looks exactly like my dead engine, however, some of the wiring coming from the alternator is different. In fact the rotor is different as well. My bike is a '97 but after a quick call to the seller, he said that the engine is a '96 (I swear he said '97 in an email). He did say that I should be able to swap the rotor section over and it should be fine. Is that so??

Cheers

T

PS He did say that he could send me the complete wiring loom if necessary...

Tupoar · Derestricted Danger Joined: 08 Jul 2011 Karma :

Just an update...

The swap of the alternator etc. was performed by a friend at my local garage successfully and the engine change is now complete.

Cheers for everyone's help...

Ed Case · World Chat Champion Joined: 01 Mar 2009 Karma :

Tupoar · Derestricted Danger Joined: 08 Jul 2011 Karma :

The engine change was a success! The bike fired up first time and everything seemed ok....

However, on my first test ride, I noticed the biting point of the clutch was very high, going into first from neutral was a nightmare and most importantly, as I tried to put sharply increase acceleration, the engine would over rev leading me to believe that the clutch is slipping. It's not so bad in 1st or 2nd but 3rd gear is not good and haven't tried any higher gears...

I've adjusted the clutch cable and lever to the max to make the the clutch pulley release as far as possible and took it out again.... still no dice.

Am I looking at a new clutch??

Cheers guys...

T

0ddball · World Chat Champion Joined: 15 Jul 2005 Karma :

Slap the clutch plates out of your old engine in.
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ZXR750L

Tupoar · Derestricted Danger Joined: 08 Jul 2011 Karma :

I'll give that a go. Is it best to swap the whole clutch assembly or just the plates??

Cheers

T

CaNsA · Super Spammer Joined: 02 Jan 2008 Karma :

Just the plates i reckon mate.

use the newer springs of the 2 sets you have though.

Tupoar · Derestricted Danger Joined: 08 Jul 2011 Karma :

Before I removed the clutch I thought I would see want others said on the forum. I found a post relating to the return spring. On the new engine, I had always thought it was a bit loose. So i thought I'd change it and see what happens. Problem solved! I'm back on the road!

Cheers to everyone for their help!