Topic: considering an (almost) complete tear-down

[Ayrity]

So, I live in florida, the later in the summer it is here, the hotter and rainier it gets. I really want to take advantage of this crappy ride time and take the engine out of the frame, and while I'm at it do a bunch of other stuff too. How much of an undertaking is this? I know it's a big job but if I stick to my shop manual and label everything as I take it apart, and have some help, it isnt out of my reach is it?

In case youre wondering, I want to strip it down to pretty much the frame, clean and repaint it black. Ill use this time to have my friend powdercoat my tank for me, and I'll paint my side covers. My friend is a master electrical engineer, and he said he would be happy to help me run new wires all over the bike (my old ones are a bit brittle and the coverings are cracking) and convert the light bulbs to led's so they take less power. I want to service the engine a bit as well, make sure that damn cam chain tensioner isnt frozen, I think it may be. and I want to dremel the valve head, and clean up the valves and pistons. Maybe even have the cylinders honed, and aligned like hondaman says in one of his tips. And also just clean EVERYTHING, there is a lot of gunk on my bike I just can't reach...

anythign else you guys would recommend I look at when I do this? any tips for when I take it apart?

[ekpent]

How is it running right now,how much money do you want to spend and are you good at finishing a big project when you get started? If it is running good and does not have any major issues I would probably just ride it until the "big one" came along and it it "needed" a teardown.More money and unforeseen problems usually during a major teardown  Good excuse to buy a spare bike though to ride 

[Ayrity]

hahaha ya it is! well, like I said im not going to take everything apart. I am good at doing things right and completing things, especially on the bike!!! Runs well now... but like I said, the summer here is like the winter up north (I didnt look to see where youre from before clicking reply lol) for me, I wear a full faced helmet, this being my first bike. So it is HOT in there.

[mystic_1]

If I may suggest, do this work in two stages.  First, do the frame and other chassis work, but don't disassemble the motor.  Do check the cam chain tensioner and anything you can do without cracking the motor open.  Once you've got the rest of the bike straightened out, then crack into the motor. 

This way, you're not working on everything at once, and you'll be able to get some riding in between the two rounds of work.

mystic_1

[Ayrity]

good, sound advice, thanks! quick question. Do I HAVE to replace the gaskets on the engine, like the valve cover, breather cover head gaskets? or if they are in good shape can I re-use? Or will I end up destroying them when I take the engine apart anyway?

[Laminar]

Do it. It's not as scary as it seems at first. I tore the bike down and put it back together in a little more than two weeks working a few evenings a week. Check my 550 thread, teardown starts here.

I reused my valve cover and breather cover gaskets without any issues.

[Ayrity]

thanks for the confidence booster. I'll document mine as well!