Sunday, February 12, 2012

How to remove Yamaha 1993 model XJ 600 Engine?

Hello i am trying to strip down my 1993 model xj 600 all the way to the frame. But i am having trouble with some bolts on the frame. According to the Haynes service and repairs manual book there are 4 front bolts that need to be removed from the bracket holding the front of the engine and one bolt at the rear right side of the engine. I have removed the rear but i am not sure if the whole bolt needs to be removed as it is unclear. Can you please advice me on what to do next after removing the rear nut? Do i have to push the rear bolt which seems to b about 12 inches?How to remove Yamaha 1993 model XJ 600 Engine?
it's more than likely a ''long through bolt'' which needs to be pushed out to the other side, it will be under load as it supports the engine. Secure the bike. tie it up to some thing so it does not fall over. You need a ''drift'' to knock the bolt back through the castings on the engine and frame. A drift is a either a steel rod 1/4 inch or more in diameter flat ended and preferably hardened, or a piece of hard wood of a smaller diameter to that of the hole. You will also need to take the weight of the bolt, prop the engine up slightly, and then tap gently with a hammer on the drift to push the bolt through. If it is very tight you will probably have to loosen all of the other bolts as well. Don't burr the end of the bolt over or you will probably not then be able to get he bolt out.

Another way to get the weight off the bolt is to get all of the fluids out of the bike so you can lay th bike down on it's side, use something like an old mattress to lay it on so you don't damage the bike. You could also put a rope on to the engine and lift it slightly so the bike wheels are still on the floor but the engine weight is supported.

Which ever way you choose make sure the bike is secured to something that will take its weight as other wise the bike can fall over whilst your crawling around under neath.
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