Job Done !
....and quite an enjoyable weekend if I say so and even more so with me never having undertaken something as big as this anyway. Have done Suspension, brakes, wishbones etc on Car but nothing major on the bike.
Anyway, picked up a '97 engine ( Mine is a '92 btw ) from a breakers in Ayrshire ( Ayrshire Bike Salvage and they are very good if you need anything remotely obscure ) Brought it home on Saturday and set about it.
I spent a night last week removing the vacuum unit, carbs, airbox, tank etc and being a noob ( but a savvy noob ) dymo taped all the parts / hoses and where they went etc which helped immensely.
Got back from Cumnock about 11am on Sat and set about the whole swap over. Taking advice as above, I changed over the non compatible parts from mine to the new one. I had to replace the Carb to Head inlet pipes, the oil filter plate and the rocker cover as the 97 had an oil inlet stub mounted in one of the rocker cover bolt holes where my 92 has the inlet fixed to the side of the rocker cover.
I disconnested all of the cables and tied them off and got a bit confused when I had a spare blue plug but couldnt locate the same plug on the new engine until I relaised it was the side stand switch.
Once that was done I managed to wrestle my engine out using a jack under the sump and a small mobile table which I sat alongside the frame. Took around 15 mins on my own as I had no one around at the time.
Got the engine out and onto a skate and well out of the way of the new one. My brother in law called by on his way back from football to help lift the new one in and was surprised when we had it in, bolted and tightened up in 5 mins ! An incredibly easy job or a pure fluke ?
He left so I set about the re-connecting. It took me until around 6pm to get everything back on the bike ( except exhausts and fairings ) so was very grateful for my labelling up of the parts etc. Hooked up the battery to test power and all seemed well. Very frustrating by this point as I didnt have an oil filter so couldnt fill her up. Had to wait until today for that.
Stuck the oil filter on at lunchtime and filled the oil up and got abit of panic on when I turned the power on and tried to start it and got nothing. Realised it was in gear
and tried again. It spluttered a bit and stalled a few times but after around 3 mins was running. Satisfied that the engine seemed ok i hooked up the exhausts again.
( Its worth noting that the reason I needed a new engine is that I wrecked an Exhaust stud in July which led to me splitting one of the stud holes in the head and not being able to remove any of the studs bar 1 ! It was cheaper to simply swap the engine out so here I was back at the original cause of the problem ) I used flange nuts this time around instead of those bloody stupid hex head nuts to re-fix the exhausts to the head with plenty of copperslip and new gaskets and they are much easier to see / locate and get torqued properly. Started the bike again and it sounds lovely. Even better than it was before ( My engine was on 33k and the new one is on 21k ).
The only bit of an issue is that the clutch from the new engine wasnt engaging properly and no ammount of fettling could get the bite and pull right so I had to re-drain it tonight and swap my old clutch in. Re filled it again ( Check your shares in BP! ) and its working like a dream.
Managed to get the lower and upper fairing back on before tea and just the screen and clean to do tomorrow. Hopefully MOT on Thursday and then back out on the road.
All in all a cracking weekend and had a few moments of surprise and times when I surprised myself ! A great learning experience to boot.
Its obscene the ammount of tools I had at the ready for this but in the end the heroes of the day were:-
> Off set head spanners
> Cordless Impact Wrench
> Halfords Mini Pro Socket Set ( Bargain £10 ( I have a big 50 piece set but this was cracking for the small stuff and hard to get bolts ))
> Me big knacking screwdriver / punch / lever / rod / lifter
Cheers for all the help from the forums too as I learnt some good stuff to set me away.
Cheers
Tone
and tried again. It spluttered a bit and stalled a few times but after around 3 mins was running. Satisfied that the engine seemed ok i hooked up the exhausts again. ( Its worth noting that the reason I needed a new engine is that I wrecked an Exhaust stud in July which led to me splitting one of the stud holes in the head and not being able to remove any of the studs bar 1 ! It was cheaper to simply swap the engine out so here I was back at the original cause of the problem ) 
