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Pulling 350 foreman engine

1614 Views 11 Replies 4 Participants Last post by  shadetree
Started working on pulling the engine out of this 86 foreman today.

One of my daughters friends brought me an 87 TRX 350 (Non D) That “needed a top end”. When he dropped it off the top and have been off the bike for years, so obviously the bottom end will need to be gone through before that engine can be used again.

My solution is to swap a good engine out of an 86 into the kids bike and then give it back to him. This 86 supposedly ran well when parked, and would fire off when I got it.

So today I went about pulling the engine from the 86. Got the four motor mount bolts out, valve cover off, header pipe off, and then hit a snag. Got one of the cam gear bolts out, and then when I tried to use the kickstart to rotate things over, apparently the kickstart doesn’t work.
I figure that will be easier to address on the bench. What’s the trick to getting this thing out? Does it need to come out one side or the other? Can it come out with the head still on and the valve cover off?

Ran out of daylight so I had to cover it up and leave it for now
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You can leave the head and rocker cover on it. Yank the sub-frame crossbar out from between the frame rails (4 bolts (or nuts? can't remember) hold it on, 2 on each side, along with the lower front motor mount bolt) in front of the motor below the exhaust. Then take the front swing arm boot loose and take the two (long, with knurled shafts on those 2 bolts for centering the carrier I think) front bolts out of the center driveshaft carrier. There is a splined sleeve near the rear of the center driveshaft that slides forward to disengage the splines. Then take the center driveshaft and carrier out. Watch for a spring... can't remember if there is a spring against that center shaft or not... Next up, loosen the rear swingarm boot band. Take all of the motor mount bolts (& one spacer) out, then lift and turn the motor toward the right side until the rear driveshaft is free and continue to drag the heavy, awkward beast out of there.
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The rear transfer case assembly stays with the motor, just take the rear swingarm boot loose and leave it be. Put those three or four bolts back it it if you've removed them. If I recall correctly, something falls apart inside the trans cases if you yank that rear housing off... don't want to deal with any surprises!
What does the “sub frame crossbar” look like?
Too many fancy words to describe one simple part... sorry about that! Number 9 on the parts fiche.
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Got a lift kit & skinnies on those old Radio Flyers yet? I need something like that to baby my old and aching back! :)
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