Engine Installation

[Wrigers]

Just some advice needed on an up and coming A4 rebuild.
Im at the point now were ive got the frame back from the powder coaters and over the weekend ive attached the swinging arm and rear shocks. Just talking to some kawa lads the other day and they recommend i go no further, fully rebuild the block and lay it on the floor, then lift the frame sideways on over the block to ease installation. Their opinion was that if i tried to get the big lump in afterwards, it would be a real struggle. Any views on this would be appreciated. Paul.

[pertonpc]

Hi Paul,
I found it easier to get the main stand and brake pedal installed before the swing arm went on.
The main stand can come up a bit higher and the spring is not such a bitch to stretch into place.
Likewise there is a danger you will mark the frame finish if you are fitting the brake lever return spring with the swing arm in the way.
Have a little test fit if you like and see what I mean.

I got the main stand on, fitted both yokes and had the forks & front wheel ready - did not have the swing arm or shocks fitted.
Then drop frame over engine, helpers lift it upright & balanced on main stand whilst I quickly slipped the forks in and the front wheel & spindle.
Soon as you have those in place it will stand self supported on main stand & front wheel & off you go.

Not fitting the swing arm means you can use an endless chain - if you do it your way you will have to rivet up a split chain on the bike.

From Mark

[z1bman]

fit the frame over the engine its much easier

[PAULJAC47]

Yep, thats the way i have always done this job,in addition lay the engine on an old easy chair cushion or similar ,cushion the frame with thin foam to avoid scratches,leave cam cover and exhaust studs off,gives you a bit of extra clearance,get an extra pair of hands to jiggle frame over engine,make sure engine bolts go in right way,take swing arm off so you can fit chain later,good luck with the buils..Paul J

[zed1015]

2 ways to do this.
Either lower the frame sideways over the fully built motor or fit the bottom end in the frame and fit the top end after.

[BigZCas]

I find the easiest way to fit the centre stand is to put the spring in place on the frame and stand, line one side up and push the bolt half in, you can use the stand as leverage to line other side and push that bolt in.
I also use the same method for the sidestand.
No streching springs over

[Wrigers]

Thanks to all, I'll adopt the methods mentioned once i sort the engine out.

[swampy]

save loads of bog roll and kitchen roll tubes for the job.
then make a cut in them down there lenthg and use them to wrap around frame tubes and tape in place.
i found this to serve very well to protect the frame during engine installation

[Garry.L]

Alternative main stand Spring Install......

http://www.kawatriple.com/tips/centerst ... spring.htm

[DavidZ1R]

Bit at a time, easy.