Motor Install

[evilFive]

Last November the motor went out on the Ninja. I purchased a used motor before spring fever bumped all the prices. I was wondering if anyone here would be willing to swap it for a nominal fee or know someone who would. The replacement motor should be here by the end of this week.

2007 ZX-6R

[Rev. That Guy]

What part of town you in? Specific bike details? Would be happy to help you swap it - you supply the brew. It's not hard, just have to pay attention and get a fsm (factory service manual) and torque specs.

- J

[vegaseric]

I've never done an engine swap, but I'd like to get in on this if Justin is there to help as well.

[got2go]

Hey!
I have one of those bikes.

What happened to the motor ?

[Rev. That Guy]

My bad. Missed the bike info.

- J

[got2go]

I have the service manual...btw...

[LVNeptune]

I would like in as well.

[The Doctor]

IN! hahaha!

[Rev. That Guy]

huh... well this spun out of control quickly.

On the level though, I would be happy to help. I will be out of town this week from thursday til sunday for a wedding in LA (yay [/sarcasm]) but anytime after that.

If just getting down to business were looking at 3-4 hours. If this is an educational experience, 5-6 although the more hands to help the better in terms of physically removing and realigning the new motor in the chassis.

What tools do you have available? I have basically everything and could lug it all to you so long as you have cold brew and access to power for the rattle gun. If Freddy has the FSM then we should have all we need.

The basic process is this:

1. Remove fairings and gas tank
2. remove intake and throttle bodies
3. remove exhaust
4. remove chain (if possible - or pull the front sprocket if it is a riveted chain)
5. drain oil/coolant
6. disconnect all electrical from motor
7. support motor and remove all frame mounts - if the swinger bolt goes through the motor case, it will be last
8. prepare new motor by checking valves (learned to do this the hard way by trusting a new used motor and it failed catastrophically) and transferring any sensors, components, ect.
9. Repeat steps 1-7 in reverse order except to fill coolant and oil last.

Also, give the motor a good once over when you get it. You will want to check for things like leaking seals or gaskets. If you have a DMM, check the stator for shorts. I would suggest fresh plugs as well. Examine for any missing components, ect. You will want to check out the top end before installation. I used a second hand ninja 250 motor in a quad project and all seemed fine until it left my wife stranded in the middle of the dunes at night. After a little CSI, i discovered that the head was full of junkyard parts (all marked up with paint pens and mis-matched) and half of the cam guide bolts were either missing or hand tight. The motor dropped a valve on the #1 after only a few hours of use. Its worth it to head these problems off. You likely will not need a new gasket for the valve cover so thats not a worry. The specs for clearances should be in the FSM and can do the valves then if need be.

All of that would be about $1500 give or take a few hundred at a shop just for labor.

I dont mind helping and enjoy tinkering... and if you or anyone else can learn something from it, all the better. Oh yeah, I control the music too. LOL. Let me know.

- Justin

[Rev. That Guy]

and dont forget, you want to get new oil and coolant as well as a new oil filter. a box of latex gloves would be appreciated by all as well

- Justin