I threw a rod last weekend and i'm picking up a good (already been checked out) replacement motor this weekend.
1. Are there any particular things to watch out for?
2. I remember something about a pin in the drive shaft that might be hard to get to (someone elaborate please).
3. I also plan on replacing the shifter seal, and both sets of coolant log o-rings and thermo. Any other seals that I should be concerned about and easier to get to now?
4. Do you put it in with or without the valve cover for clearance?
5. Any other clearance issues or a better way to do something vs. the OEM and Haynes manuals?
6. Leave the upper fairing on?
7. Does the swing arm need to be unbolted or removed?
8. Whats a realistic amount of hours i'm looking at to do the swap? I'm pretty handy in the shop and have all the tools.
Ironically, I just did the carbs 2 weeks ago. I'm going to start the tear down tonight.
2. when you pull the boot back and turn the shaft you will see a small hole, use a small drift or something to push the pin in SLIGHTLY as you pull the drive shaft out
3. you may want to replace the blance shaft seal at the same time
6. leave the upper on
7. yes, unless you want to take the cylinder head off, I did mine a few years ago and left the rear end alone, since I was taking it apart anyway it saved some labour but it's a fussy fit. Patience is the key word. you may want to take the alternator and the starter off to remove some weight. Adjust the valves before you put it in.
That's about all I can remember, getting old and foggy!
Colin Prior has done quite a few, perhaps you can email him
