top end rebuild/engine removal? - Yamaha Grizzly Forum : GrizzlyOwners.Com Yamaha Grizzly Forums


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Old 08-20-2009, 01:56 PM   #1 (permalink)
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Default top end rebuild/engine removal?

Its time this winter to do a top end rebuild on my 05 660. I was looking through a manual i got from ebay and it says that the engine needs removed from the frame to do a piston/rings, valve seal, top end rebuild..... I just finished a rebuild on a polaris scrambler( i know different animal), and its can be done with the engine in the frame... so my question is i guess, if i have all the plastic off, the tank, and other misc. stuff do i really need to take the entire engine out of the frame for this? it just kinda seems excessive.
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Old 08-20-2009, 02:24 PM   #2 (permalink)
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DANG !!! ... I sure hope it can be done in the frame, cause I'm gett'in my parts together to do the same work & I figured I could do it with the motor in the frame ......... DANG !!!!
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Old 08-20-2009, 02:26 PM   #3 (permalink)
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i know..... it was fairly easy with the engine in the polaris but the way its showing in the grizzly everything is a little more cramped.......
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Old 08-20-2009, 02:33 PM   #4 (permalink)
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To tell ya the truth, I haven't even looked at the frame & the position of the motor ... I just figured ...... I guess i got to use to do'in everything to my Banshee with the motor was in the frame, that I assumed the Grizz would be the same way.

You know, I had head to change the front diff pinion seal, ya had to take the front diff out of the frame .... Well, I changed the seal with the diff in the frame .... so no axle removal, etc .... a little cramped maybe, but saved me a LOT of work.

Hopefully, the motor will be the same way .....
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Old 08-20-2009, 03:50 PM   #5 (permalink)
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i did the top end in a Kodiak with the engine in the frame with no problems at all. I'm sure some of it may have been easier on a workbench, but not enough to warrant removing the engine.
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Old 08-20-2009, 08:17 PM   #6 (permalink)
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The top end can be done with the engine still in the frame. Much easier on a bench, but not needed.
You don't even need to remove the front plastics. If your going to go that far it's actually easier to remove the motor than the front plastics. I just pulled my motor out again to re-torque everything.

Have to remove Left footrest and side covers. On mine the left rear lower a-arm mounts and lower shock mount for same arm had to be unbolted to get access to the rear diff bolts, unbolt rear diff and pull back to drop the rear drive shaft. I left the rear motor mounts attached to frame but un-bolted from block. Front motr mounts stayed attached to block. Lift whole motor up and to the rear to drop the front drive shaft. Unplug all wiring connected to block and comes right out.
To remove front plastics means to un-plug almost every single connector from the wiring harness. Not a tough job, but those connectors can be tough to get apart and break fairly easy.

Might want to do the sheaves and wet clutch in the bike unless you have a motor stand to bolt it too. Trying to get leverage to break those bolts loose is a pain with the motor rocking around on a bench. Same goes for the magneto rotor and gears on the other side, but none of that needs to be removed unless crank is coming out.
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Old 08-21-2009, 12:01 AM   #7 (permalink)
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Hillbrigger, where was this post two weeks ago when I did my top end. I pulled the front plastic, snorkles and all. What a pain in the butt. Next time will be your way. Thanks for the helpful info.
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Old 08-21-2009, 02:16 AM   #8 (permalink)
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JJ, sorry, just did this on monday. There was no way I was taking the front plastics off AGAIN! lol
Oh and those clutch vent/snorkels are real treat trying to get in once you've put the plastics and motor back in place. Same with the rear brake vent. That one is almost impossible but can be done if you have a daughter with mini hands. :P
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Old 08-21-2009, 08:14 AM   #9 (permalink)
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Removing all of the bodywork just seems to be the worst part of any Grizzly project. It does give you a chance to make sure that there's no mud, grit, grime or grease to fall into whatever you've torn apart though...
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Old 08-22-2009, 09:52 PM   #10 (permalink)
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Thanks for all the tips Hillbrigger .... WHEN I get around to it, I'll try to do mine in the frame ... and yes, I may regret it .... we'll see .... [img]/CFIDE/scripts/ajax/FCKeditor/editor/images/smiley/msn/confused_smile.gif[/img]
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