Now ive had a days rest its write up time..
Day 1:
I took a friend upup on the offer of a 2003 engine with 23k miles on it and he agreed to deliver it, he turned up on a lovely soaking wet pissing it down day and helped load it into the l200 and off i went..
first task was remove the old engine...
so much had to come off it was unreal.. took me a whole day to take off the parts to get the engine out but i ran out of time and couldn't be bothered after smashing my hands to bits...
ended up removing all rad hoses, coils, many plugs, radiator, engine mounts, obvious seat and tank, rear side panels due to wiring and exhaust...
day 2:
set about removing the engine only to find the carbs had to come completely out just moving them didn't work and this took ages!! an hour later it was free... then had to remove thermostat housing and oil filter as there was next to no room to move it...
after much pissing around and lifting and pulling it finaly gave up and came out... at this point i didn't see the point in the engine mounts!
new engine time.. dragged new engine and this was a royal pain in the arse!! the bit the oil filter screws onto kept catching the frame.. trying to hold up and engine whilst wiggling into a hole barely big enough seemed impossible but it eventually popped in and i set about rebuilding..
went together fairly well until i hit the airbox and carbs... bit of oil on the rubbers the carbs went in no problem.. the airbox on the other hand, 45 minutes later i admitted defeat and went to bed.
Day 3:
First thing i did was attack the airbox, it had to be done.. rather than doing the easy bits first i wanted it out the way so i got a jack handle and beat the living daylights out of it until it eventually popped on
now to tackle the front engine mount again.. 3 bolt holes in a triangle formation... do they all line up.. do they heck! half hour of bashing moving lifting and smashing my knuckles i went mad and ripped my crash bars off snapping both bolts for the crash bars.. clearly wouldn't of helped in a crash!! the holes finally lined up
now all i had left was to empty the old oil, cut off and change some plus as they changed a few plugs on the 2003 engine and reconnect radiator and hoses + exhaust...
Rad on no problemo... hoses easy! exhaust... nope.. wouldnt do up properly then i noticed the biggest ballache possible..
how did i not see this before... so off it went and got drilled out and replaced..
went to bed had eough!!
Day 4:
new shiny stud and the exhaust went on
oil drained out of the new engine...
New oil filter and topped up with oil and water moment of truth...
Battery is dead
charged battery take 2... not firing... trace wires back and eany meany miny mo... changed 2 round and we have a spark.. started up for about 5 seconds then died, tried again and idled fine just a little rough, took about 10 minutes to warm up then sounded great untill i noticed a pool of water.. ffs!!
Rad hose was leaking, took it off changed it and still leaking... took it off again and its still leaking... gloves are off!!! final time new longer hose super tight and its done!!!
Topped water up and let it idle for 10 minutes with no problems, rode it home absolutely perfect except the gear lever being a bit too high!
A job which id allotted 1-2 days on ended up taking 4 due to many small things being an absolute pain and taking much longer than they needed to! hindered by the horrible weather and stupidly tight bolts.
i now have a 2003 engine with around 23000 miles on it
all thats left is to get the front fairing resprayed AGAIN! then put the stickers on.
Topic: fzs 600 engine change, its done :) (Read 6933 times)
