I may have misspoke if I mentioned "special" tools as many of you already have most of these tools. After my house fire, I only had a basic set requiring me to go out and buy new ones. The ones I bought included two torque wrenches (foot/pound and inch/pound), large sockets (22mm-36mm), clutch tool, brake line bleeder, a spanner wrench (I think that's what it was called), socket allen wrenches, T-50 Torx bit, a hub puller (I think that's what it's called), and a few other things I'm not remembering right now. I did need a torque-angle wrench for the crankcase bolts, but I borrowed that from a friend.
There were no tools required that would have no other uses except the clutch tool. It is very specific. I've also never needed a T-50 Torx before, but now I have one. I've used hub pullers before, and had one before the fire, so that one isn't specific either.
Actual time in labor is a shot in the dark. I took a full day getting the engine ready to pull. This included removing the fairing, radiator, water pump, oil cooler, starter, air box, throttle bodies, etc. But a "full day" includes taking pictures, eating lunch, taking the kids to school, surfing the forum, listening to my wife, buying new tools (this was a huge time killer), etc. If I had to do it today, I could probably do the same thing in 1-2 hours.
I took about 4-5 hours actually taking the engine apart. But, this also included cleaning off bench space for all the parts, going to the store to buy parts, etc. Splitting the cases is actually not too difficult. The biggest challenge, and I was warned about it by a friend, is that the service manual will say something like, "Middle Gear Step 1, Crankcase - See Crankcase", but when you look at the Crankcase section, it discusses complete and total disassembly. So, much of my time was evaluating exactly what part of the crankcase disassembly was required, and what was not to accomplish my goal. I mean, if I followed the service manual, when I disassembled the crankcase, I would have had the crankshaft out too, and I didn't have to go there. Again, if I had to do it today, it would probably only take 1-2 hours.
Actually removing the tranny took maybe 30 minutes, half of which was just looking at it to see if it was as easy as it looked. Like I said, they've engineered this to be almost easy.
Reassembly of parts took me about an hour. I left the tranny in stock form, lined up all my new pieces (using part numbers to verify my visual comparison -
see this thread to see what I mean) and then as I disassembled the stock tranny, I would reassemble it with the new parts.
Buttoning up the engine took me about 2-3 hours. Several times, I would do things without looking at the service manual because it was straightforward only to read the manual later and realize I didn't add grease or lube, etc where needed. That ate up some time.
I spent the better part of 4 hours trying to put the motor back in the bike by myself. While I now know it can be done, at the time, I wasn't willing to risk tilting the engine on my jack to get the final drive shaft over the lip to slide it in. After four hours, I was extremely frustrated and decided to go to a movie. My friend came over and we had the engine lined up in a matter of 3-4 minutes.
I then spent about 4 hours putting everything back on. I also completely tore off the front fairing when I started because I wanted to explore the limited space up front for future HID install. If I hadn't done that, putting everything back together would have taken an hour less I'm guessing.
So, Reader's Digest, a day to remove engine. A half day to split cases and ID parts. A half day to reassemble parts and a half day to put engine back in.
If I had to do it again, I'm guessing total actual time working on it would be about 10 hours.
But, here's the deal. If I did something wrong and I have a failure due to something I may have overlooked, I'm not going to do it again! I'll be too busy running in circles pulling out my hair screaming, "AAAAAAHHHHHHHHHHH"
I keep telling my wife that now that I've saved $2000 I should be able to spend that on something else, but she's better with money than I am and says not a chance
But I did get more tools, so that's a bonus.
