How To Build A Motorcycle Engine? [A Step-by-step Guide] 


How To Build A Motorcycle Engine

The engine is the primary source of power to operate a motorcycle. People consider this device as the powerhouse of the vehicle. That is why a flawless engine is the most important device to experience perfect bike riding. For this reason, you need to know how to build a motorcycle engine.

If you need to build, modify or rebuild the machine of your roadster, you must follow a set of certain rules. You have to make sure the device works fluently and provides your bike with sufficient energy. This is a very sensitive task, and you must be very careful in every step of making the power generator. For better results, you should keep patience and concentration. 

However, I had a passion for creating the power generator for my motorcycle on my own. In this article, I will share my experience of how I did it. Hopefully, after reading this article, you will also be able to build one.

9 Simple Steps To Build A Motorcycle Engine: The Perfect Way

You can make the engine for your beloved motorbike in your garage. I did it by myself by following a sequence of steps. To build this inevitable machine, you have to follow the set of rules I have described below. So, follow the below 9 steps to building your motorcycle engine by yourself:

Step-1: Collect Necessary Tools

First of all, you should buy a manual book for building your motorbike engine. And obviously, you have to buy the parts of the device individually. Then collect the machine measuring tools from inspecting and indicating the parts. You also need a digital caliper, micrometers, and a mechanical wrench to tighten the bolts.

After that, you need to collect a feeler gauge, a dial bore gauge, and a set of piston ring compressors. Try to collect a box of new tap and die sets. The tap and die set will provide you with a lot of bolts in every shape and size. After that, you have to bring a valve spring compressor and a gasket scraper. 

A heavy-duty machine stand will keep your device safe while building it. Sockets, shallow, and ratchets will also help you to construct the instrument more quickly. And lastly, you need a bunch of screwdrivers so that you can tighten screws of every size.

Step-2: Inspect And Clean The Parts

The first task is to collect the necessary equipment. And when you have collected them, you need to inspect them carefully. Sometimes you may find jammed or rusty equipment in your garage. Clear the rusts and make them suitable for your upcoming instrument. 

You can use dust cleaners or brush to remove the rustiness from the metals. Remember, if the construction materials are not properly inspected, the result of the construction will never be satisfactory. You may rebuild the instrument again and make your installation difficult later. 

Step-3: Install The Header Pipe

Once you are ready to do the job, you have to install the header pipe first to the frame of your power supplier. The header pipes or muffler of the device holds all the nuts, clamps, bolts, and strings that you will set later. Before moving to the next step, make sure that the header pipe has all the scopes to attach to the frame. Just take a simple note on a piece of paper and keep it aside.

Step-4: Air Box Installation

The next task is to install the air box separately. Spray a WD40 into the float chamber of the box and make it clean and clear. Place a perfect piece of bolts on the top corner of the box and do the same to the bottom. Create a proper channel to connect it to the fuel tank. After that, join the parts with a set of screws and tighten them with a screwdriver. Seal it in a plastic bag, and don’t let air insert inside the air box.

Step-5: Attach A Final Drive

The final drive will set the torque measurements for your engine. The device will have huge support from this device. Try to use a gasket or sealant to attach it to the source. There are a lot of tiny bolts you need to tighten there. Use an adequate wrench to tighten them. 

Attach the port to install a chain there. You have to add a section to connect the gearbox there. Connect a rubber gaiter at the front part of the driver so that it can gain permission to the shaft. Then use the appropriate bolt to create a bond between the parts and keep the drive aside.

Step-6: Set The Cases And Clutch

At this step, you have to make a clutch plate and some cases, to hold the individual parts you have built before. Measure the size of the parts and set the cases accordingly. Use a special clutch case holding tool to organize the port for a nut. Make sure to leave a place for the oil lines.

In addition to this, you have to install an alternator to the case so that the oil lines fit in the case. After that, you have to place the air box and the final drive in the cases and connect the clutch with the drive. Make sure the joints are properly sealed and connected in a safe space.

Step-7: Connect Electrical Plugs

First and foremost, keep in mind that you have to select different colored electrical wires to connect different engine parts. This will help you recognize the wires when you need to recreate them again. Try to label the wires so that you don’t forget the function. Sometimes you need to attach multi-pin plugs to join them to the machine.

Step-8: Tighten The Mounting Bolts

You have to tighten the mounting bolts. Use the feeler gauge and dial gauge to install the bolts accurately. Keep all the accessories on the heavy-duty stand of the machine. Use the tap and die set to select the adequate bolts for the gaps. Tighten them with an appropriate screwdriver. 

After that, examine all the bolts you have joined with the frame and make sure the joints are properly attached. Connect the oil line and prepare a perfect space on the nearby bench. Measure each particle with the caliper and recheck them with the manual book.

Step-9: Finishing Tasks

Lastly, you need to set the engine with the fuel tank. Connect it with a source of electricity. Then start the device. Check the sound and examine if there is any leak in the system. Try to use a torchlight to find any leakage in the oil line. After that, take the newly built power supplier to a dark place and run it there. 

Check the electrical joints to see if there is any spark in the joints. Then attach the frame of the machine to it. Your building of the engine is complete. Now it’s all set to convert the kinetic energy into power for your bike and give you an enjoyable ride.

Tips You Can Follow To Build A Motorcycle Engine In A Quicker Way

Building the engine for your bike is not an easy task if you don’t follow proper guidelines. You should be very patient while completing the construction step by step. However, the following tips will help you make your process quicker and more comfortable:

Tip-1: Help Of A User Manual

A user manual is a book that contains photos of the parts and particles of the machine with a detailed discussion. Try to read the book top to bottom to clear your concept. Identify the parts and follow the process to attach them. The book will be different for various types of engines. Select the best one for your motorcycle and create it accordingly.

Tip-2: Take Pictures Or Notes

When you attach the parts with the connectors, try to take pictures or keep notes about them. Write down every detail or code number of the wires you joined earlier. If you need to rebuild the machine again, you can use those pictures or notes to remember the details. Likewise, if you make any mistakes in the first attempt, those notes will help you to recover quickly. 

Tip-3: Build It In Your Garage

Try to build the power supplier in your garage so you don’t have to move it further. After you attach the individual parts altogether, the machine’s weight will automatically increase. You will find it difficult to move it and set it on your bike if you make it somewhere else. On the other hand, building it in the garage will help you to arrange and assemble the tools easily.

Tip-4: Use A Zipped Bag

You need a plastic bag with a zipper. Generally, you have to work with numerous bolts, nuts, and screws to construct an engine for your motorcycle. Additionally, there are a lot of tiny parts that need to be arranged, and you should never lose any of them. If you keep those essential parts in a zipped bag, you will easily find them when you need them.

Tip-5: Always Use Hand Gloves

Keep in mind to use a pair of hand gloves before starting your engineering work. You have to work with some sharp and heavy tools like screwdrivers, wrenches, and gauges. They can be injurious to your hand if you misplace them while operating. A thickly layered glove can protect your hand from getting damaged. 

Mistakes You Should Avoid While Building A Motorcycle Engine

Unfortunately, mistakes can happen, and your motorcycle engine cannot be built. Here are the mistakes you should avoid while working on this project.

  • Don’t Lose Any Part:

Don’t lose any part of the engine while you construct it. There are a lot of tiny instruments, and you have to attach them individually. If any of them is lost, you need to buy them again. Additionally, if you misplace anything, you will have to open the power converter again and reconstruct it. Therefore, restore the particles to a suitable place from where you can find them easily.

  • Try Not To Misplace Anything:

Read the manual book well and follow the process above so that you don’t misplace anything. If you lose any serious part, the device will not work properly. It can even cause sparklings and fire the instrument. The machine will burn the wires. That can lose you a huge amount of money. So be careful and recheck everything before installing it.

  • Never Hammer The Joints:

Sometimes you may find it difficult to tighten the screws, nuts, or bolts with a screwdriver or a wrench. In this case, never use a hammer to tighten them. This can damage the frame or break the bolts. Try a newer bolt or nut that will fit easily in that place. Try a different screwdriver or wrench to place them perfectly. Don’t damage them with a hammer.

  • Don’t Use Lubricants:

Using lubricants will make it easy to tighten the screws, but it will make you suffer in the long run. Lubricant is a highly flammable product. The friction between the pistons of the machine will make a fire inside the air box if they touch the lubricants. So avoid using it. You can use other options instead.

  • Never Leave The Bolts Loose:

Make sure that you have tightened all the bolts and nuts perfectly. If you leave any of them loose, it might cause huge internal damage to the device. Somehow, if the piston gets touched with any removed particle inside the drive, that can burst into pieces and cause terrible damage to your bike. In addition, you have a huge possibility of getting injured also.

Related Questions:

Can You Build Your Motorcycle Engine On Your Own?

You can build your motorcycle engine on your own at your garage. All you need is to buy some necessary tools to attach the machine’s parts. Keep your patience high. If you are passionate enough and you have adequate time, it is quite easy for you to create a customized powerhouse for your bike.

However, you should always ensure your safety while working with the tools. Remember to use the specific nuts and bolts where they are needed. Try to follow a guidebook or take assistance from your partner. Be cautious while buying the particles. Do not start creating the machine without being properly prepared. 

How Long Does It Take To Build A Motorbike Engine?

It may take 6 to 8 hours minimum to build a motorbike machine. Installing the parts is a time-consuming process, and it needs your proper concentration. If you hurry to make the process quicker, you may commit any kind of unwanted mistake that could backfire negatively.

In addition, it will test the level of your patience. As you need to work with tiny tools, it may be a disturbing and boring task for you to do. For this reason, you need to be slow but steady to construct the essential device for your roadster. When you sum up all these things, you have already spent at least 6 hours of your life.

How Much Does It Cost To Build A Motorcycle Engine?

It will cost about $4000 to $6000 to build a motorbike engine. To be honest, it will depend on the type of device that you are to make. The cost may vary from different models, types, or sizes of the individual parts. You may have to buy some equipment also if you don’t have them in your garage.

Though the price range is not fixed, it is quite clear that building a power supplier for your roadster is not a cheap task to do. You should spend a huge amount of money in this case. But if you have ambition, nothing matters. So, don’t look at the price, respond to your dream.

Is It Safe To Build An Engine For Your Bike At Your Home?

Establishing a motorcycle powerhouse at your home is not safe if you do not take proper caution before starting the job. It is better to install the parts in your garage. 

Sometimes it can spark while attaching the wires to the drive. And if you are in your house, it can result in causing a serious accident. So, try not to create the machine in your house rather than do it in the garage.

What Does An Engine Of A Motorbike Consist Of?

Generally, a bike’s engine consists of some pistons, a vast cylinder block, and a head. There are some other minor parts too. They contain some spokes and ports in their body. The major part of the machine also contains a valve train. It lets the oil line attach to the drive. 

That creates a spark and results in an explosion. This explosion starts the piston running up and down. These movements create energy inside the device and utilize the power to run the vehicle properly. Although the construction materials may vary from engine to engine, these basic parts are the same in most of them.

Can You Ride A Motorcycle With A Homemade Engine?

You can ride a roadster run by a homemade engine. The only concern is you have to maintain the machine properly. Try to follow all the prescribed rules accurately and step by step from the very beginning till the machine is properly built. Do not add anything extra that can harm your device.

But first of all, you have to make sure that the dike is comfortable with its powerhouse. Check the fuel efficiency regularly. If your bike is compatible with the power converter, then you can carry on with that. But if you find anything unnecessary, you may have to replace some particular portions and recreate the instrument again.

Which Material Is Best For Engine Block?

Genuine GM Performance is one of the best front-engine block cover kits. This cover kit provides you with the highest standard material available in the market right now. It also delivers the most purified iron sheet on its outer part and ensures the best possible fitness. 

This cover kit includes a harness and camshaft sensor, a beautiful cover gasket, and a crankshaft seal for the front part of the device. You will also have some nuts and bolts preliminarily attached with it without any cost. The best feature of this cover kit is that you can use it on most engine blocks.

Closing Remarks:

You must have an appropriate mindset to build a motorcycle engine perfectly. Try to keep the process simple and make it a positive way. Be cautious in installing every piece of parts and particles in the machine. Check the device properly before inserting it into the frame.

Run the engine and examine it before installing it on your bike. However, if you properly maintain the suggestions, I hope it will be easier for you to customize the source of the power of your roadster. Happy riding!

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Ahsan Ullah

Hi guys, This is Ahsan Ullah. I have been riding motorcycle for more than 15 years. In this long period, I have experienced a lot of things about bike riding. Now I am trying to share my experience with you on this website.

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