11 replies to this topic

[SteveUhOh]

So, i'm gonna have to remove the engine out of my 04' mxz 800, just curious if someone could give me a quick breakdown of what i'm gonna have to do to accomplish this, i don't have a user manual, and i'm hoping i wont have to buy one, i'm just looking for some tips and advice.

[Yamadoo500]

Take carbs off, disconnect all gas, oil, coolant lines, unplug all wires, remove Y-pipe, remove mounting bolts, take clutches off, take recoil off, unplug spark plug wires. Can't think of much more than that, it's a pretty easy project. You may find that taking pictures will help you get it all back together correctly.

[Goughie]

^ Everything in the above post except that i've never had to take the recoil off before? Unless you mean just untie the rope ( make sure to tie a knot so it dosent suck in the recoil. But i've had my motor out 5 times in the last year and have never taking the entire recoil assembly off.Don't worry or fret over the wiring and plugs. They all pretty much only plug into one spot so its hard to go wrong, would very much recommend you drain the oil/coolant with a nice turkey baster and hose. It saves sooo much of a mess and cleanup for the sake of 5minutes.

Edit: The motor is going to come out the clutch side of the sled, with 2 people its pretty easy. ive even had to do it alone >.< ( not fun at all ). and the motor goes back in the same way, a little wiggling and manuevering and she should pop right out. after a few times it seems like it slides right in and out haha.

[watchthis907]

Take carbs off, disconnect all gas, oil, coolant lines, unplug all wires, remove Y-pipe, remove mounting bolts, take clutches off, take recoil off, unplug spark plug wires. Can't think of much more than that, it's a pretty easy project. You may find that taking pictures will help you get it all back together correctly.

are you joking?

[watchthis907]

this is how I remove an engine.1)Pull the pipe and can.Y-pipe can stay..
2)Pop the air box out,then pop the carbs outta the boots
3)Unhook the throttle cable.Set carbs aside.
4)Un hook the two first plugs on the mpem.
5)Now unbolt the 4 motor mounts.
6After its the motor is loose is when I disconnect the coolant and oil lines.
7)disconnect throttle cable at the handle bar lever.(that is best for installation b/c you can set your oil cable on the bench)

[Yamadoo500]

are you joking?

No, actually that's how I did mine.

[Yamadoo500]

^ Everything in the above post except that i've never had to take the recoil off before? Unless you mean just untie the rope ( make sure to tie a knot so it dosent suck in the recoil. But i've had my motor out 5 times in the last year and have never taking the entire recoil assembly off.Don't worry or fret over the wiring and plugs. They all pretty much only plug into one spot so its hard to go wrong, would very much recommend you drain the oil/coolant with a nice turkey baster and hose. It saves sooo much of a mess and cleanup for the sake of 5minutes.

Edit: The motor is going to come out the clutch side of the sled, with 2 people its pretty easy. ive even had to do it alone >.< ( not fun at all ). and the motor goes back in the same way, a little wiggling and manuevering and she should pop right out. after a few times it seems like it slides right in and out haha.

I just took the recoil off because my whole motor was coming apart anyways for a rebuild, so i do stand corrected on that. You probably want 2 guys on the job, although it can be done by yourself it isn't as easy.

[rampage]

7)disconnect throttle cable at the handle bar lever.(that is best for installation b/c you can set your oil cable on the bench)

Great tip, I can't believe I've never thought of that. Hooking up the oil cable when the motor is already in is the part I hate the most, I always lose that stupid little clip.

The only other tip I would give for a REV is that sometimes the shafts that go through the motor mount will spin so the bolt on one side won't come out, it just spins the shaft. If that happens, you need to re-tighten up the other bolt that does come out, then take the 'stuck' bolt all the way out. Then put the stuck bolt all the way back in, and keep going back and forth between tight and loose on each side until both bolts come out. Helps to have an impact gun.

[SteveUhOh]

Thanks for the tips much appreciated, all information is valuable, so thanks for posting.

[jeff 800 ho]

I like that tip on the throttle cable also. To me getting that cable/e-clip on the oil pump SUCKED the most also.

[IQR670]

A flat a beer will get it done also lol Maybe invest into some ziplock bags to hold nuts a bolts and label them if this your first run around, nothing worst putting something back together and not having that one NUT/BOLT missing and it always seems to be the one you need to finish the job.

[Yamadoo500]

A flat a beer will get it done also lol Maybe invest into some ziplock bags to hold nuts a bolts and label them if this your first run around, nothing worst putting something back together and not having that one NUT/BOLT missing and it always seems to be the one you need to finish the job.

X2 on the bags or baby food jars work well labeled.