How do i remove my kawasaki kx 80 engine out of the bike?

Question

year of the bike is 1986

Answer 1

makes it a bit easier to remove seat & tank to give you clearer access.  

then remove the springs holding the expansion chamber (pipe) from the cylinder and mounting bolts that hold the muffler / spark arrestor to remove the exhaust completely.

then start removing clutch cable, disconnect coil and any other wiring.  loosen rear axle & chain tensioners so you can take the chain off the counter shaft sprocket.

then disconnect the carb from the air filter box and the boot going into the back of the cylinder (leave the carb intact on the end of throttle cable)

Then start removing the engine mounting bolts.  it might be a bit of a tight squeeze to remove the entire engine as a complete unit.  typically, you can remove the head bolts (or nuts?), and base bolts (or nuts?) to slide the cylinder off the piston (piston should be at the bottom of it's stroke to allow more clearance of the cylinder removal within the frame).  immediately stuff a couple of rags into the top of the engine cases around the connecting rod to prevent debris from falling into the crank area (learned that one the hard way when about 15 years old).

it should be fairly easy to remove the engine out of the frame at this point.

click here http://www.bikebandit.com/houseofmotorcy... and then you can click thru all the exploded diagrams to see how all the different parts fit together including the frame and engine mounting bolts.

it's really not that hard with a few basic tools and a metric socket set ... and a little time.

another key note ... pay close attention how everything comes a part as you will have to re-assemble at some point in time... might not be the same day and then it's hard to remember where everything came off and in what order.

not good to remove and re-install and have parts left over (been there done that several times)...

good luck!!!

Answer 2

real simple, i have taken bike engines out in as little as  30 minutes, just disconnect all cables, wiring, chain, exhaust, then unbolt all of the engine mounts, then the motor will come right out

you will find it is rather simple, and will give you confidence in what you are doing

Answer 3

drop kick it till it falls out. thats what i do.

Answer 4

undress it (take off exhaust, cables etc)

take off engine bolts

try to remove, realize it won't move, look for more bolts

find more bolts, take them off

try to remove again, still won't move, look again

two more bolts, remove them as well

proceed to have engine nearly drop out of the bike.

(make sure you've taken out all the mounting bolts >.<)