Motor swap 05 s2r

[karrotx]

Well, I bought an 05 s2r and was scammed. There's a bent output shaft and DucPond wants $1862 to replace it.

I found a motor on ebay that I can have for $850. The bike has 4340 on it and this motor has 4500; seems like a pretty good fit.

I've never swapped a motor before, what tools will I need. Will I need a torque wrench? Any advice? How easy is it to take the motor out of a monster?

Thanks!

[Slide Panda]

Did you find the same engine?

Yes, you'll need a torque wrench.. and then some.  You'll need some way to suspend the bike, since the swing arm is attached to the case.  Possibly a jack for the engine - though I've seen some folks remove the suspension and headers, then lower the rest of the bike to the floor to drop the engine.

It's not rocket science, but it'll be a lot of work, even more if you're gathering tools or bodging a lift as part of the process.  It means tanking apart a large bulk of the bike.

[needtorque]

It really isnt that bad and with any mechanical competence can be done in well under a day if you dont care about cleanliness. If you were cleaning everything and making it look like new then one long hard day or two slower ones.


Remove in this order:

Seat
tank
Battery/airbox
throttle bodies
Exhaust
put the weight of the engine on a home made stand. 
support the rear of the frame from above
break the chain
remove clutch slave cylinder
remove rear swingarm, wheel and shock attached (if you remove the center bolt for the shock/adjuster link pivot arm it all comes down as a unit)
unplug all electrical connectors that you can find
find more connectors that I know you missed the first time
remove frame/engine mount bolts
begin lifting the frame off the engine
start seeing all the connectors you missed the first 2 times
assembly is the reverse of tear down





PS
I left off all the stripped bolts, broken knuckles and tools, and cursing that are sure to accompany this endeavor

PSS
Dont forget things like painting anything you want painted while it's torn down, making the frame and new engine sparkle as new, good time to PC the swingarm if you have the desire/funds, and rerouting of the wiring harness as well.  Also, mods like a light flywheel install would have their place here.

[numbskull]

+11ty on the torque wrench. The fasteners have specific torque ratings that need to be adhered to. It's way too easy to overtorque aluminum.

[ducatiz]

that sucks ass, i hope you went after the seller..

[He Man]

that sucks ass, i hope you went after the seller..

+1, Id hunt him down before i start tearing/buying anything apart.

[Slide Panda]

Remove in this order:
...
break the chain
remove clutch slave cylinder

Remove the slave
Do Not break the chain - slack the chain as much as possible
Remove the front spocket
Slip off chain.

It's a little wonkier on the SSS bikes, due to the eccentric hub.  But if you get enough slack you can work the chain  off the front sprocket sufficiently that you can slide the sprocket off the output shaft w/o needing to break the chain. 

[rockaduc]

that sucks ass, i hope you went after the seller..

+11ty billion, was it a private party sale or through FeeBay?   Inquiring minds want to know more about this unfortunate situation.

[karrotx]

Thanks for all the advice!

I'm not sure I can suspend the rear from above, can I use a rear stand?

How to build the motor support? Is the goal to support the motor, unbolt everything, and then lift the frame off of the motor?

The story is in GMF but I'll recap. I bought an 05 s2r from a guy in Ohio (I live in Virginia). I called him, he stated it was in great mechanical condition "needs nothing, ready to ride." SO... I drove 6 hours to Cleveland and took it for a test ride. He mentioned that there was no gas in the bike (ON PURPOSE!  ). The bike seemed fine to me, shifted great, and it got up there. I didn't get to spend enough time with it. On my way back into his neighborhood the bike started to shake like it was out of gas; at the time I expected this. I was wrong, it turns out it has a bent output shaft. I contacted the seller and asked him to pay for half the shop bill ($1826) he quickly responded with "you're screwed, your word against mine"

It's either pay the shop for 17 hours of labor to replace the bent output shaft or get a used motor and do the swap. Then I can try to recoup the cost by selling the broken motor (stating the problem, of course).

Any other advice I'll greatly appreciate!

Also, what do you recommend for the torque wrench?

[Slide Panda]

I'm not sure I can suspend the rear from above, can I use a rear stand?

How to build the motor support? Is the goal to support the motor, unbolt everything, and then lift the frame off of the motor?

Also, what do you recommend for the torque wrench?

That sucks that the seller is such a douche.

You probably could used a rear stand, to a point.  But remeber, that the engine is a stressed member and the mount for the swing arm, so you cannot drop the engine just using a rear stand, sicne you should have removed the wheel and rear suspension already.  It's easiest to suspend the rear portion of the frame.  I've seen folks do it a few ways - from rafters, 2x4 cross beam between 2 ladders, even using a saw horse or 2.

Support for the engines really no big deal once the headers are off.  A few sections of 2x4 will prop it up weel enough and keep the oil filter off the ground (if you didn't pull it). 

If I was doing it, I'd have a scissor jack and a way to suspend the bike.  Lift up the rear so the wheels just off the ground and then run the jack up to the lever of the engine and have it out. 

If you've good some friends, they could life the rear while you slide blocking under the engine that's tall enough to take the load of the bike.  But you've still got to deal with the issue of loosing the suspension.  But if your buddies are willing to hang out for a while they can do all the holding up of the frame while you disconnect the suspension and engine from the frame

An important part is getting the weight of the engine to be held up by something other than the frame, or else the bolts are not coming out. 

How much do you want to spend on a torque wrench? If 'not much' a dual beam from sears (about $30) is a good bet.  By all accounts quite accurate - but you don't get a ratchet head and you have to watch the beam guage.  Most times not a big deal, but in cramped spaces or akward angles you may have problems.

The craftsman clicker types work pretty well (they are what I have) and are a good choice for the shade tree wrencher.

[DarkStaR]

Not to be mean, buy it sounds like you may be "biting off more than you can chew" with this motor swap.

...
I've never swapped a motor before, what tools will I need. Will I need a torque wrench? Any advice? How easy is it to take the motor out of a monster?
...

[MotoCreations]

A couple of notes:

- remove all the bodywork / tank / etc from your S2R
- go label all the wiring harness and where the connectors go.  Then take pictures of everything! and how it routes through the frame / locations / etc.
- remove the battery
- remove the wiring harness
- take more pictures and then remove the exhaust
- take more pictures and remove the airbox and fuel injectors (add more labels if needed)
- take more pictures and then remove the swingarm / rear wheel / shock

All you will have left is an engine, frame and front suspension/wheel

Remove the engine -- you should only have the two bolts left holding it.  Get friends to help for this step.

clean the frame and inspect everything BEFORE you re-assemble. 

Swap the engine then.  (use your friends again to  help)

Get some blue/purple and red Loctite for thread/fasteners and use a torque wrench as you put fasteners back in.

Re-install everything in the reverse order you took it apart.

Do a "wrench check" and verify all your fasteners/nuts/bolts are tight.

Test fire it.

Once done, route it to the dealership to tune/adjust the injection system to verify everything works correctly.  It's cheap insurance.

Then you should be able to go ride it and have fun like you originally intended.

Be prepared to spend some money on tools, stands, torque wrench, etc.  You will use for decades and it is a good investment for yourself.

Remember -- taking pictures is cheap insurance.  Digital pictures are cheap!  So take an insanely amount from different angles for yourself to reference if needed later.  Take pictures while disassembling items as you go as well -- thus you have a reference for spacers/shims if needed later for reassembly.

And have fun while doing this -- it isn't hard.  Just time consuming. 

[karrotx]

Thanks for all the great advice!

One question the, do I actually have to remove the wiring harness?

[KnightofNi]

don't be skeered. it's basically just removing a lot of bolts and unplugging connectors.

when i dropped the motor on mine i put it up on stands, raised a platform for the engine to rest on with some blocks, unhooked everything, then raised the frame of the bike of the engine and took out the blocks supporting the engine platform.

do make sure you label things as it makes reassembly MUCH easier.

take your time, find the correct tool for the job, and ask before you do something if you aren't certain.


speaking of which....ohh stu, i have a question...

[needtorque]

You are not removing the wiring harness.  You only disconnect the connectors attached to anything coming off the bike during the process.  You can then just move the harness around as necessary to drop the engine out.