Engine swap tips wanted (Daytona 675)
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Engine swap tips wanted (Daytona 675)
2009
Hi thanks for all the input on previous thread on my stuttering Daytona.
During the ongoing investigation I found 'shavings' in the oil and it turns out the cam and cam holder is shot. I dont believe this is the root of the problem but it has to be fixed. After getting a quote for the job I decided a engine swap would be more ecconomical. I've picked up a 8k mile engine, mine is 25k.
I've never taken on such a task before but armed with a camera (before shots) and a trusty Haynes manual I'm going to give it a try.
I looking for any tips and tricks, no matter how obvious you think they are including what types of greese, lubricants to use on the different parts of the engine and electrical to use. The engine didn't come with the alternator but I've changed one before on my FZ6. I know I will have to reset the tps after the build which i can do.
Thanks in advance
Hi thanks for all the input on previous thread on my stuttering Daytona.
During the ongoing investigation I found 'shavings' in the oil and it turns out the cam and cam holder is shot. I dont believe this is the root of the problem but it has to be fixed. After getting a quote for the job I decided a engine swap would be more ecconomical. I've picked up a 8k mile engine, mine is 25k.
I've never taken on such a task before but armed with a camera (before shots) and a trusty Haynes manual I'm going to give it a try.
I looking for any tips and tricks, no matter how obvious you think they are including what types of greese, lubricants to use on the different parts of the engine and electrical to use. The engine didn't come with the alternator but I've changed one before on my FZ6. I know I will have to reset the tps after the build which i can do.
Thanks in advance
- billinom8s
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Re: Engine swap tips wanted (Daytona 675)
Take lots of pics
Make lots of notes
Bag up sections of stuff you remove
Place nuts and washers onto any bolts they come from
Place bolts back into holes they came from when removing bits
Refer to the manual for which bolts require copper slip and which require threadlock.
If a bolt is hard to remove, check the manual to see if it went in with threadlock on it.
When rebuilding, check Torque figures - they provide them for a reason.
Take your time, it's only a race when your mate passes you.
Clean as you go
Enjoy it
Make lots of notes
Bag up sections of stuff you remove
Place nuts and washers onto any bolts they come from
Place bolts back into holes they came from when removing bits
Refer to the manual for which bolts require copper slip and which require threadlock.
If a bolt is hard to remove, check the manual to see if it went in with threadlock on it.
When rebuilding, check Torque figures - they provide them for a reason.
Take your time, it's only a race when your mate passes you.
Clean as you go
Enjoy it
07977507395
don't forget we are onX and Instagrambelieve it or not !!!
southwestbikers@southwestbikers (original, I know.)
KTM 990 superduke R,
Zx10r trackbike, ktm 350 excf muddy
Suspension and bike work undertaken.
don't forget we are onX and Instagrambelieve it or not !!!
southwestbikers@southwestbikers (original, I know.)
KTM 990 superduke R,
Zx10r trackbike, ktm 350 excf muddy
Suspension and bike work undertaken.
Re: Engine swap tips wanted (Daytona 675)
Grab yourself lots of Chinese pots for bolts and bits,
And a roll of masking tape for plugs to write where they fitted into with a little flag.
Keep everything clean and organised and if you can lay it out in order, ie if I part got removed place it there and then next part beside it and so on. This way when rebuilding your going to know the next bit to refit.
And a roll of masking tape for plugs to write where they fitted into with a little flag.
Keep everything clean and organised and if you can lay it out in order, ie if I part got removed place it there and then next part beside it and so on. This way when rebuilding your going to know the next bit to refit.
"Welding is like cheese on toast! It gets hot and sticks together"
- billinom8s
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- Posts: 19907
- Joined: Sep 10th, '05, 22:31
- First Name: simon
- Location: Teignmouth
Re: Engine swap tips wanted (Daytona 675)
if i'm doing a job like that then the pasting table comes out, a towel put onto it(stops things rolling away) and then, like ruffian said, bits get put down in order.
07977507395
don't forget we are onX and Instagrambelieve it or not !!!
southwestbikers@southwestbikers (original, I know.)
KTM 990 superduke R,
Zx10r trackbike, ktm 350 excf muddy
Suspension and bike work undertaken.
don't forget we are onX and Instagrambelieve it or not !!!
southwestbikers@southwestbikers (original, I know.)
KTM 990 superduke R,
Zx10r trackbike, ktm 350 excf muddy
Suspension and bike work undertaken.
Re: Engine swap tips wanted (Daytona 675)
Work space is key.
Clean area to work and plenty of space to store the removed parts, or at least a good system of boxing and storing parts.
Clean area to work and plenty of space to store the removed parts, or at least a good system of boxing and storing parts.
1190 Adventure S, 990 Superduke, DRZ-400E - all the bases covered.
Re: Engine swap tips wanted (Daytona 675)
Try to do the job in a short period of time, like over the weekend. If you take it apart and leave in bits for a week or two, it becomes alot harder.
I'd normally have my head in the manual and writing notes the week before. YouTube can be a big help too.
Decent torque wrench is a must.
Undo the sprocket first.
I'd normally have my head in the manual and writing notes the week before. YouTube can be a big help too.
Decent torque wrench is a must.
Undo the sprocket first.
ST4
DRZ400e
DRZ400e
- billinom8s
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- Posts: 19907
- Joined: Sep 10th, '05, 22:31
- First Name: simon
- Location: Teignmouth
Re: Engine swap tips wanted (Daytona 675)
sprocket nut?Ducaki wrote: Undo the sprocket first.
07977507395
don't forget we are onX and Instagrambelieve it or not !!!
southwestbikers@southwestbikers (original, I know.)
KTM 990 superduke R,
Zx10r trackbike, ktm 350 excf muddy
Suspension and bike work undertaken.
don't forget we are onX and Instagrambelieve it or not !!!
southwestbikers@southwestbikers (original, I know.)
KTM 990 superduke R,
Zx10r trackbike, ktm 350 excf muddy
Suspension and bike work undertaken.
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Re: Engine swap tips wanted (Daytona 675)
Diagrams and photos as you go too.... you always think, I'll remember that goes that way or that shim went in that position, what ever.... just label identify and record. And Good luck!!!!
Don't care who you are, how much you have, how powerful you are. You still sit on the toilet with your pants around your ankles. Yep, it's a level playing field..
- TLS-Moose
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Re: Engine swap tips wanted (Daytona 675)
Surely very little beyond bodywork actually has to come off?
Loosen gearbox sprocket first of all.
Disconnect clutch cable & gear shift linkage at engine end.
Loosen throttle bodies on stubs
Remove exhaust
Disconnect generator/pick up at nearest connectors
Disconnect coolant hoses at engine end
Disconnect oil cooler, if it has one, at engine end
Undo engine bolts (minding toes)
Reverse process.
Go ride. Take a magnet with you for the bits you didn't tighten up enough
Loosen gearbox sprocket first of all.
Disconnect clutch cable & gear shift linkage at engine end.
Loosen throttle bodies on stubs
Remove exhaust
Disconnect generator/pick up at nearest connectors
Disconnect coolant hoses at engine end
Disconnect oil cooler, if it has one, at engine end
Undo engine bolts (minding toes)
Reverse process.
Go ride. Take a magnet with you for the bits you didn't tighten up enough
Of all the things I have ever lost, I miss my mind the most .....
Handle stressful situations like a dog - If you can't eat it or play with it, pee on it and walk away
Handle stressful situations like a dog - If you can't eat it or play with it, pee on it and walk away
- ptolemyx
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Re: Engine swap tips wanted (Daytona 675)
Lucky for you it's a little Trumpet. You need a crowbar and bodybuilding friend to get a Busa/B-King motor out
P.S. a magnet's no good for the aluminium bits that fall off
P.S. a magnet's no good for the aluminium bits that fall off
old and disgraceful so doing what I can while I can before I can't
07949879213
07949879213
- billinom8s
- Site Admin
- Posts: 19907
- Joined: Sep 10th, '05, 22:31
- First Name: simon
- Location: Teignmouth
Re: Engine swap tips wanted (Daytona 675)
I thought they were made of wood.
07977507395
don't forget we are onX and Instagrambelieve it or not !!!
southwestbikers@southwestbikers (original, I know.)
KTM 990 superduke R,
Zx10r trackbike, ktm 350 excf muddy
Suspension and bike work undertaken.
don't forget we are onX and Instagrambelieve it or not !!!
southwestbikers@southwestbikers (original, I know.)
KTM 990 superduke R,
Zx10r trackbike, ktm 350 excf muddy
Suspension and bike work undertaken.
Re: Engine swap tips wanted (Daytona 675)
What happened to the old engine in the end??
"Welding is like cheese on toast! It gets hot and sticks together"
Re: Engine swap tips wanted (Daytona 675)
Check out the electrical connectors as you go. Mine was only 6yrs old (kwak not trumpet) but one of the injector connections wasn't clean and it took ages to find.