what's your preferred reassembly order for a completely torn down bike?

Jessezm

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Just curious, do you all have a preferred order for reassembling an XS650? I am waiting on fork ears to come back from the painter so putting the front end together now would entail some reassembly once those parts come in in a couple weeks, but in the meantime I want to make progress.

Engine is back together and ready for install, front forks are rebuilt, and rear wheel should be ready to install this weekend once I finish truing. So now I'm getting ready to start doing stuff. I was thinking I would do the engine first so I can do that sideways frame installation. But then what's the best move from there? Is it tricky to get the wheels and forks on with the weight of the engine already in the frame?

Also, what about the wiring harness -- is there anything that needs to go on one side of the engine or the other that can't be re-routed after install?

Just looking for basic tips and no-nos/lessons learned so I don't have to pay the dumb tax first!

Thanks!
 
This is a seriouly good question! Something new and out of the ordinary.
Yes engine install first. Swingarm next. Forks/front end. Place on stand for wheels install. Wire up. Fenders. Maybe place engine/ frame assembly on stand then swingarm, etc....
 
Good stuff! Swing arm is already on but that shouldn't interfere with the engine mounting I don't think. Other thoughts? Thanks!
 
Nope! Press on! Take pics and post 'em!
 
interesting..... I prefer to have the frame on it's wheels... then install the engine...and all it's goodies and hook it up.
that way I can move the machine around.....
but I think it's just a personal preference thing.... there is no set order in stone that I know of,
..... if everything is off the frame it may be easier to install the engine first by laying it on its side over the engine and then putting the bolts in
and use the frame to lift it into the upright position.... however that makes putting on the rear swing arm a bit more difficult because of the heavier frame...... I just man handled my engine In and out of the frame while it was on the center stand anyway it was hard as the engine is really heavy all on it's own . I turn 65 this year and I'm out'a shape but if I can lift the engine up off the floor and get it in the frame without mashing fingers I think most people could. <grin>:laughing:
......
Bob.........
 
Like Bob I prefer engine last. Unlike Bob I can't set a motor in with brute strength. I use a forked bracket bolted to the head motor mounts and a come along suspended from above.
 
I carried that damn engine down to the basement and set her on the bench, than hauled her back up by myself, but it probably shaved a year or two off the end of my life!
 
Yah I bet you DID !!!!!:yikes:
it was aIl I could do to get it the 8" or so up off the floor with the engine assembled !
I had the advantage of having the head and cylinders off when I put it on the work bench ....so I cheated ! LOL
..... I enlisted my Kid to help me get it from the work bench to the floor near the bike frame.... that helped a bunch !
the engine is down right HEAVY I dunno how much it weighs but I'ed say it's 90% of the bikes total weight ! that's why I don't think you can lighten a xs650 much ....all the weight is in the engine ! LOL
Once upon a time I could'a handled that weight ok.... but not any more ...... Retirement makes a fella soft ! LOL
......
Bob........
 
I put the engine into the roller, no problem. I think that was in 1980, had I needed to build it 3 years ago when the bike came back, I likely would have parted the XS1 out. john
 
Here's my take on this. I have an XS1b, according to the manual the engine weighs 135 lbs. I have completely stripped the bike down and now reassembling. For me the method was to lay the engine on its right side with a 2x to support the jugs and make the engine kind of level on the floor (don't forget something to protect the cases against the floor). I then lifted the bare frame with only the center stand attached (I'm 62 and not so difficult) and placed it around the engine, aligned the bottom bolt and rear bolt and set them in place. I then extended the center stand and lifted the bike up off the floor so that it was on the stand only, had to kind of balance it there. A 6x6 (about 14" long) fits perfectly between the frame where the front motor bolt gussets are located, once upright the frame with engine balanced perfectly between the center stand and the 6x6 at the front of the engine (on the gussets). I can provide a pic if you like. Once upright you can assemble what you like, I started with the rear. For me the idea was to keep it all as light weight as possible until upright and this method was really much easier than trying to wrestle a 135lb motor into an upright frame. BTW I did that all on my own.
 
I built mine as a roller then hoisted the engine into the frame and used a floor jack under the engine to raise and position it in the frame. During the rebuild I used a furniture dolly to roll the engine around and rolled it right up to the frame before I lifted it in. There's many ways to do it but pick one that's not gonna cripple you...
 
IMG_20161015_101211_284.jpg
 
Yes engine install first. Swing arm if you have one, front end, wheels, wiring is my order.
I lay the engine sideways on the ground on a blanket. then lay the frame sideways over it and bolt it up then I turn the frame with the engine right side up.
Beats the hell out of muscling the engine in and trying to left and wedge it.
 
seat first ..........so I can sit down and have a think every time I get stuck :)
 
but you can't contemplate the bike good On it ....ya gott'a look at it while your thinking about it ! for that, I made a shop stool ! that way I can take a load off my feet while staring at the bike and thinking what can I do next !!!!!!! LOL:laugh2:

......
Bob......
 
but you can't contemplate the bike good On it ....ya gott'a look at it while your thinking about it ! for that, I made a shop stool ! that way I can take a load off my feet while staring at the bike and thinking what can I do next !!!!!!! LOL:laugh2:

slippery slope Bob....:) pretty soon you'll have your TV,.... rocking chair and slippers in there

......
Bob......
 
That'll never happen ! I go out to the shop to get away from the TV !!!!! ..... now the computer I might consider ! LOL
.... but actually I am getting OLD and I accept that.... so I do things at MY speed nothing wrong with getting old as it happens to all of us sooner or later
the question is can you do it without it effecting your personality in an adverse way or not..... and for me .... the jury is still out ! LOL
..... it's one thing to grow old and realise you can't keep up like you used to, ya don't have the streingth you used to have and the hearing goes to hell
as well as the eye sight..... but if your lucky and health still abides in you your still the same o'l you you were when you were 20 yrs old.... its just the body has a bunch of miles on it ! ....
there is no doubt getting old sux ! .... But what's the alternative ????? LOL
......
Bob.........
 
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