Changing an engine

[Paul]

Has anyone changed an engine on an FZS600?


If so how easy / difficult is it?


And what's the easiest way of getting an engine out or in?

[Dead Eye]

Changing the engine is fairly straight forward and you should be able to do it yourself with a reasonable set of tools - nothing overly specialised is needed but basically some decent fitting sockets, screwdrivers, a hydraulic jack is handy for holding the engine (best to put a bit of wood between the sump and the jack though), a rubber mallet could come in handy, torque wrench is good for tightening everything back up again to spec as well as loosening some of the tighter ones (though a breaker bar is handy as well). A couple of larger sockets are necessary; I have a 24mm, 30mm and 32mm - I think I used them all for various tasks but I was doing slightly more than just removing the engine.

I followed the Haynes manual for the procedure and it was fairly straight forward. Did it myself in a day without ever having done it before, got it back in in a day as well with the help of a friend (but you could probably do it yourself as well).

One thing the Haynes didn't mention is that its a lot easier to slide the engine in and out of the frame if you remove the oil cooler on the front of the engine first; this is why I went and bought the 30mm socket

If you get stuck, just give us a shout and I'm sure someone will be along to answer

[Fazerider]

Yes, quite a few of us have done it.
It's not really difficult, just a long job. Once you've disconnected everything bar the engine mounts support it the weight with blocks of wood or a car jack and wriggle it out of the right hand side of the frame... preferably onto a raised platform so you only need worry about the sideways movement at that stage. It's heavy, but liftable single handed unless you're very feeble or carrying an injury.

[Andy Clap]

Put a good releasing oil on the exhaust studs and let it soak in for as long as you can.  Maybe even heat-and-repeat if you can.

[Paul]

To Dead Eye


I've just looked at the engine, but I can't see an oil cooler.


I've got a radiator, but I can't see an oil cooler.


Just as 'aside' which side did you pull the engine out?

[red98]

oil cooler is at the base of the oil filter 

[Paul]

To Red 98


Do you mean the round thing that the oil filter screws on to?

[red98]

yeh thats the one,haynes manual 2.11......you got any piccies DEADEYE

[Paul]

Thanks for that.


So pull it out of the right hand side of the frame and remove the oil cooler.

[Dead Eye]

The engine will only pull out of the right hand side of the frame so that's your only option basically

As for piccies; see this http://foc-u.co.uk/index.php/topic,5990....l#msg54915

The nut in the photo is securing the oil cooler to the front of the engine. It really wasn't obvious (to me at least) that it was an oil cooler to start with, but it is It has a water jacket fed by the radiator system to cool the oil as it circulates through the filter

This is from when I had to take my engine out because of snapped exhaust studs

For a slightly more extreme method of removing an engine, see this thread http://foc-u.co.uk/index.php/topic,6969....l#msg66151

(In this instance I lifted the frame off of the engine haha)

[Paul]

To Dead Eye


Are you really trying to restore that............. well that, burnt out wreck of a Fazer?

[Dead Eye]

I really really am

There are different levels of commitment at this stage - I will definitely be restoring the engine and that's making progress. I'm about half way through grinding the valves back in to the head and they are looking a lot better than they do in those photos If I'm lucky I'll have that done this weekend, but my friend has got me rebuilding all of his brakes on his car...

Restoring the entire bike has a significant amount of cost attached so that will depend accordingly - I have new wheels and front fairing (though it needs spraying). Its things like, chain and sprockets, calipers, swing arm and many other bits that are mounting up to be very expensive. Plus I need new carbs :lol

Edit: The carbs reference is from what happened; http://foc-u.co.uk/index.php/topic,5294....l#msg46062

As it turns out, all the bits I gave away I kind of need to try and re-acquire... woops

[Paul]

To Dead Eye

Forgive my curiosity, but how did it happen?

[Dead Eye]

I think it was mentioned in the thread I linked; basically the leading theory (not proven and I'll remind everyone of that fact :lol ) is the homebrew ultrasonic bath caught fire (sander strapped to a box) and then everything went with it... still can't fathom how it got so severe so quickly but at least the fuel tank didn't explode  :eek

[Paul]

Home Brew Ultra sonic bath?


I do home brew, I have my own still, but I don't get what's that to do with motorcycles?

[Dead Eye]

I was using it to clean the carburettors which I had off, so the bike was in bits in the garage. This was a rented property as well and I'd moved in literally 5 days earlier... thankfully I wasn't immediately evicted :lol