One Man Engine Install - Is it possible?

In the home made tools thread there is a handle some one built to remove/install engines. It has a U shape on one end that bolts to the front and rear mounts. The other end has a tee handle. In the middle is a loop to attach it to a chain hoist. Hooke the tool to the engine, hook up the chain hoist. With a bit of lift and pull the engine comes right out.
No place for a chain hoist, use an office chair under the tool.
Leo
 
I'm 59 years old and I have removed and installed an engine in my XS with no problems and it is so easy a child could do it my way. And there is no way I could do this by lifting
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the video is the first time I ever pulled the engine
 
I wrestled that thing in last night. This is in no way a brag, just saying it can be done if you are 3 beers deep and utterly desperate to get your engine in. Take your time, you won't have a choice, haha.
 
figure8 said:
I wrestled that thing in last night. This is in no way a brag, just saying it can be done if you are 3 beers deep and utterly desperate to get your engine in. Take your time, you won't have a choice, haha.
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Yes, of course it can be done with one person, but it may just be a day or two before the lower back pain starts:)
 
i've done several CB450's, 500T's, Yam TX500's, XS's, all the way to a GS1000 alone. at 57, this may just be a bad idea, but there is never anyone around. wives don't really appreciate lifting motors so they don't count...

i've never tried the lay the frame over the motor approach because i always build a rolling chassis first. i consider it a better order to get all frame, wheel and suspension mods sorted out without the weight of the motor in frame.

bike is clamped/tied to bench as per pic (gas tank removed). wrap your frame in used padded packing envelopes or similar and use masking tape as required. test any tape on your fresh paint for any peel up etc and remove it right after motor is in. almost impossible not to nick frame somewhere, btw...

if you have a little plywood platform about the same height as lower frame rails it's very helpful to set motor on so install is more a two step thing. pre-plan your moves with all bolts nuts and plates laid out correctly. a piece of board and car scissor jack underneath works ok for "fine" adjustment to get a first bolt through, the rest are easier.

not a pleasant process but doable.
 

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MacMcMacmac said:
I lifted my Seca 650 engine in and out by myself, so the XS should be easy.
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No, its not easy, for one person, to lift a 150 lb. XS650 engine into a frame. Everytime someone posts that they lifted an engine into a frame by themselves, I sense their male ego is making a statement.

When I worked in an industrial utility plant, as I remember, one person was only allowed to lift 55 lbs. maximum. There was a reason for that. It was to prevent worker injuries.
You can and should always get a second person, and use some mechanical device to assist if possible. As part of my previous job, I used to instruct at safety meetings, and proper lifting practices was part of that, so I can't resist commenting on this post.

http://www.xs650.com/forum/showthread.php?t=37&page=4
 
By that math you need 3 people to lift out the motor. Or 2 and 2/3's, I rounded to 3 because of posted engine weights of 180 lb.s.
 
weekendrider said:
By that math you need 3 people to lift out the motor. Or 2 and 2/3's, I rounded to 3 because of posted engine weights of 180 lb.s.
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Well the 55 lb. rule was for the industrial utility plant. Once you go above that, you would be using an air or electric hoist, or a fork lift, or a crane of some type.

Now in your home garage, some common sense needs to come into it. With the XS650 engine weight around 150 to 160 lbs., I considered it safe for my son and
myself (80 lbs each) to lift out an engine.
 
Having a few years left (fingers crossed :wink2:), and being reeeeeeeally stubborn, generous usage of towels, pipe insulation, and tape, patience, milk crate + wood blocking, gloves, centerstand helpful, but not necessary......Dry (no oil inside engine). Removal (or postponing installation) of: starter (kick and/or elec), clutch and cover, LH cover and charging sys,
shoehorning can be accomplished successfully without audience or injury.....
 
TwoManyXS1Bs said:
Uh-oh...
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Haha, I'm fine with that. Am I happy I was able to do it, yes. But the real truth is I was tired of my buddy flaking out and I really wanted to get it in. I did a couple test lifts to get my hand positioning where I thought would work best then just went for it. It took some finesse to get it into position to drop in the motor mounts but nothing to crazy. My post was really just to show other reasonably able bodied guys they could probably do it if they were desperate, which I was. Would I prefer another set of hands, of course. But then again now that I know what a mans man I really am, I'll just do it myself. [emoji23]
 
weekendrider said:
They don't have common sense at utility plants?
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Correct, they don't have common sense. In Nuclear Generating Stations they operate under a set of very rigid rules, for the safety of the general public and the plant workers.

Even with all the rules and training, workers get injured. I saw a guy limping, and grimacing, as he left the plant at the end of his shift. He had lifted too much weight or lifted incorrectly, and partially crushed a disc in the lower back, which puts pressure on the sciatic nerve. These kind of injuries can be very long lasting and painful.
 
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RG- i get what you're saying, but the home garage is not an industrial setting with purpose built materials handling tools and fixtures... even with an assistant ya gotta reach across and through the frame and the XS motor (and most motors) must be tilted in to the frame a bit anyway. that makes it difficult to use an overhead come-along etc... as the cable interferes with the frame. it took years for frames to evolve to the easier sportbike orientation.

trying to pull/install a motor solo with the whole bike on a lift would be just about impossible. on the floor it's not too bad. get directly over the lift and use the legs not the back...
 
barncat said:
RG- i get what you're saying, but the home garage is not an industrial setting with purpose built materials handling tools and fixtures... even with an assistant ya gotta reach across and through the frame and the XS motor (and most motors) must be tilted in to the frame a bit anyway. that makes it difficult to use an overhead come-along etc... as the cable interferes with the frame. it took years for frames to evolve to the easier sportbike orientation.

trying to pull/install a motor solo with the whole bike on a lift would be just about impossible. on the floor it's not too bad. get directly over the lift and use the legs not the back...
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Its not as difficult as you say. Yes, it should be done with the bike on the floor, not on a lift. Here's a picture of a simple and inexpensive way for 2 people to lift an engine into and out of the frame. 2 pipes and 2 nylon slings. You don't have to struggle or get your body into any odd position.
 

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I have purpose-built lift handles, similar to what RG used, but with attachment tabs welded on .....

MotorHandles.jpg


MotorHandles2.jpg


With a helper, they make engine removal and install pretty easy. Once removed, I have some smaller handles to aid in moving the loose motor around. There's really nothing to grab onto on these motors. Yes, those buckhorn handlebars are good for something, lol .....

DHandles3.jpg


DHandles2.jpg


DHandles.jpg


I'm in the process of building a one man removal/install "cart". I don't have a way to hang any lifting device over head so this is my solution. The cart will roll up next to and under the bike. It will have two long arms that reach in and attach to the front and rear motor mounts. The arms will pivot on another length of round stock so I can simply "lever" the engine up and out. All the lifting parts will have adjustments for height, length, width, angle, etc. The base is the bottom from an old shopping cart I found in a ditch along the side of the road. No pics yet but I will get some soon.
 

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