bike tear down/removing motor

[martyk]

I think I have finally just decided to drop the motor so I can paint the bike frame. Just wondering if there is anyone in the norwood or surrounding areas who have done this before and could either lend a hand (just so I have someone experienced) or who just just help with giving some advice.

Im hoping to have it dropped before christmas. Its an 2003 kawasaki 636 and is currently on stands with plastics, rims, exhaust off.

thanks in advance and thanks to everyone who wants to give me shit...bahumbug to you too!!

[Degsy]

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You're going to need some special tools that I probably have. You can borrow what you need from me. Also, get a service manual and do what it says in the order it says. Remove all fluids first,

[PinHead]

I have never pulled a motor out of a 636, but I could give you a hand sometime if you need.
I'm in the next town over.
BTW.. get a few muffin trays for small hardware and masking tape and sharpie for labeling stuff.

[martyk]

alright Degsy I 'll look up the service manual at work tonight. Meant to hit you up this week but got caught up with working extra.

pinhead; already on top of the labeling, got a box of sandwich bags and a ton of boxes to keep stuff organized. Im sort of hoping to just drop the motor in place with hopes of not having to disconnect everything

[CBR929RE]

well you're gonna have to disconnect all the electrical stuff from the motor and pull the harness out of the frame. and you'll have to drain the coolant and probably oil too. otherwise dropping the motor shouldn't be too difficult.

[hondarider102]

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I have the service manual if you want to borrow it

[martyk]

I will see if i can find it online/more local but if i cant i'll hit you up

[martyk]

Printed the manual off line, over 500 pages!! Glad it was a printer at work

[DucDave]

pictures....take 'em as you go...

[stoinkythepig]

Printed the manual off line, over 500 pages!! Glad it was a printer at work

If you follow the factory manual, the work will be very easy. My best tip is to support the engine from below (make a cradle out of scrap wood) and lift the bike off of it rather than lower the engine from the bike. With the wheels, tank and bodywork off, the remainder of the bike minus the engine weighs very little.

While it's apart, you should swap the steering head bearings out. So easy in that state.

[martyk]

might leave the front fork on, still undecided on that but we shall see, got all 500+ pages of the manual so messing with the bearings shouldnt be too hard

[stoinkythepig]

might leave the front fork on, still undecided on that but we shall see, got all 500+ pages of the manual so messing with the bearings shouldnt be too hard

If you are going to paint the frame, the forks/triple really should come off. It would take less time than masking them for paint. Taking them off is VERY simple.

I've seen steering head bearing last less than 10,000 miles and as long as 70,000 miles. They can be a pain to change when the desire is to take as little apart as possible, but in your situation, they are pathetically easy to get to. Pretty cheap too.

Take pictures of hose and cable routing, the manual diagrams for that are good, but augmenting them with photos is ideal.

Leave the throttle cables attached to the carbs/throttle bodies, only docsconnect them at the handlebars.

Good luck with your project, it'll be fun and educational.