Topic: My engine installation plan of attack!

[JHansen]

Good News!

The motor on my 400f is ready to put back in the frame after almost 3 years. Motor is sitting on my bench, complete, and it looks beautiful! My friends can stop already with all the unfinished project jokes, I've finally had enough!

Here is my plan for getting it back in the frame, see if you fellas can poke any holes in it, or maybe you have suggestions I haven't thought of.

My plan is to install on the right (rear brake pedal) side of the bike. I have not fitted the oil pan yet, and was planning on putting that on once the motor is in. Can this be done? The motor will also be sans carbs, breather cap and oil filter housing. The motor came out with the oil pan still on the motor, but I think it will be easier to reinstall if I don't have to clear over that, then just crawl under the bike and put it on. Or is it more trouble to put the pan back on once the motor is in?I plan on having at least one helper with me, that's what it took to get it out. Should I have 2?

Lastly, anyone have a stock 4 into 1 exhaust in decent condition mouldering around somewheres for sale? I pulled mine out of storage tonight. I was planning on running on it for at least this year, but it is definitely showing it's age, and I fear it will horrible next to my freshly painted and polished motor. I am only lookinf for stock pipes, nothing aftermarket. 

With any luck, the motor will go in Wednesday night, Thursday at the latest! Finally get to ride!!!

Wish me luck--- Geronimo!!!!

John

[DiscoEd]

I can't speak for the 400f, but on my 550 I have done it some thing like this...

1.) Remove oil filter assembly. (this is Very important!)
(I did not find it necessary to remove the oil pan)

2.) Gently lay motor over on its right hand side (points cover to the floor)

3.) Very delicately lay the frame over the engine and gently ease is ito a posisiton where you can line up one of the front bolt holes.

4.) Place the front engine mounting plate (the one toward the floor as frame is laying on its side) in place Insert a bolt into the frame and leave it loose.

5.) Next insert a bolt up through the mounting plate and into the mounting hole in the engine. put on the nut but leave it loose.

6.) Try to work the same trick with the mounting plate and bolts on the upper side.

7.) Next work in one of the bolts through the frame and the rear of the engine. put on the nut but leave it loose.

8.) This should alow you to put the whole thing upright.  Proceed to put in and tighten all nuts and bolts.

You might want to put down some pretty good soft towels or rags under the engine and frame to prevent scratching anything. Especailly when putting  it upright. I have done this with no additional helpers and it seems to work. (I'm not a large person.)

Regards,
DiscoEd

[grumburg]

Just installed motor in my 550 last week. Covered frame with rags from horn to battery box and wrapped paper towl tubes around rags and taped them. Wrapped manifold studs with tape. Set motor in place (breather cover removed) . Let motor rest on frame and raised into position with floor jack. Inserted back bolts first, then bottom, then front letting the jack support weight. Took 20 minutes and did not scratch a thing .

[JHansen]

Congratulations! Oil pan in or out before install?

[grumburg]

Oil pan on.

[Bodi]

Leave the oil pan off, it makes it a lot easier to get the motor in. I have tried to remove/install the 400F motor with it on, and never succeeded. Pretty easy with it off. It goes in from the right side, the frame tab on the left gets in the way.
You can do it alone but it's much better with help. The 400 is light enough to handle but it is very awkward and you can't see whet you're doing very well.
Wrap rags around the frame tubes to help prevent damaging the paint.