Engine Removal
- Support the rear part of the swingarm with a stand.
- Squeeze the brake lever slowly and hold it with a band [A].
Warning: Be sure to hold the front brake when removing the engine, or the motorcycle may fall over. It could cause an accident and injury.
![](https://motoinstruction.ru/img/kawasaki/23/128614.jpg)
Caution: Be sure to hold the front brake when removing the engine, or the motorcycle may fall over. The engine or the motorcycle could be damaged.
Drain:
- Engine Oil (See Engine Oil Change in the Periodic Maintenance chapter)
- Coolant (See Coolant Change in the Periodic Maintenance chapter)
Remove:
- Seat (See Seat Removal in the Frame chapter)
- Middle Fairings (See Middle Fairing Removal in the Frame chapter)
- Front Frame Cover (See Front Frame Cover Removal in the Frame chapter)
- Side Cover (See Side Cover Removal in the Frame chapter)
- Rear Frame Covers (See Frame Cover) Removal in the Frame chapter)
- Lower Fairings (See Lower Fairing Removal in the Frame chapter)
- Radiator (See Radiator and Radiator Fan Removal in the Cooling System chapter)
- Exhaust Pipe (See Exhaust Pipe Removal in the Engine Top End chapter)
- Muffler Body (See Muffler Body Removal in the Engine Top End chapter)
- Remove the bolts [A] and right lower fairing bracket [B].
- Remove the left lower fairing bracket in the same way as right.
![](https://motoinstruction.ru/img/kawasaki/23/128615.jpg)
- Disconnect the crankshaft sensor lead connector [A].
- Remove the clutch cable lower end [B] (See Clutch Cable Removal in the Clutch chapter).
![](https://motoinstruction.ru/img/kawasaki/23/128616.jpg)
Remove:
- Fuel Tank (See Fuel Tank Removal in the Fuel System (DFI) chapter)
- Air Switching Valve (See Air Switching Valve Removal in the Engine Top End chapter)
- Air Cleaner Housing (See Air Cleaner Housing Removal in the Fuel System (DFI) chapter)
- Throttle Body Assy (See Throttle Body Assy Removal in the Fuel System (DFI) chapter)
- Stick Coils [A] (see Stick Coi (Ignition Coil together with Spark Plug Cap) Removal in the Electrical System chapter)
- Bolts [B]
- Baffle Plate [C]
- For models equipped with an ABS, open the clamps [D].
![](https://motoinstruction.ru/img/kawasaki/23/128617.jpg)
Remove:
- Starter Motor Cable Terminal Nut [A]
- Engine Ground Cable Terminal Bolt [B]
![](https://motoinstruction.ru/img/kawasaki/23/128618.jpg)
Disconnect:
- Water Temperature Sensor Lead Connector [A]
- Alternator Lead Connector [B]
- Sidestand Switch Lead Connector [C]
- Speed Sensor Lead Connector [D]
![](https://motoinstruction.ru/img/kawasaki/23/128619.jpg)
Remove:
- Engine Sprocket (See Engine Sprocket Removal in the Final Drive chapter)
- Bolt [A]
- Shift Lever [B]
- Disconnect the neutral switch lead connector [C].
![](https://motoinstruction.ru/img/kawasaki/23/128620.jpg)
- Open the clamp [A].
- Disconnect the horn leads [B].
![](https://motoinstruction.ru/img/kawasaki/23/128621.jpg)
- Support the engine with a suitable stand [A].
Put a plank [B] onto the suitable stand for engine balance.
Remove:
- Front Engine Mounting Bolts [C] (Both Sides)
- Engine Mounting Bracket Bolts [D] (Both Sides)
- Rear Engine Mounting Nuts [E]
- Pull out the rear engine mounting bolts from the left side.
- Using the stand, take out the engine.
![](https://motoinstruction.ru/img/kawasaki/23/128622.jpg)
Engine Installation
- Firstly, insert the rear engine mounting bolts [A] from the left side of the engine.
- Secondly, temporally tighten the right engine mounting bracket bolts [B] and then the right front engine mounting bolt [C].
Position the collar [D] as shown.
- Thirdly, temporally tighten the left engine mounting bracket bolts [E] and then the left front engine mounting bolt [F].
- Fourthly, temporally tighten the rear engine mounting nuts [G].
- Fifthly, tighten the rear engine mounting nuts.
Torque - Rear Engine Mounting Nuts: 44 Nm (4.5 kgf·m 32 ft·lb)
- Sixthly, tighten the right engine mounting bracket bolts.
Torque - Engine Mounting Bracket Bolts: 25 Nm (2.5 kgf·m 18 ft·lb)
- Seventhly, tighten the right front engine mounting bolt.
Torque - Front Engine Mounting Bolt: 44 N·m (4.5 kgf·m 32 ft·lb)
- Eighthly, tighten the left engine mounting bracket bolts.
Torque - Engine Mounting Bracket Bolts: 25 №m (2.5 kgf·m 18 ft·lb)
- Lastly, tighten the left front engine mounting bolt.
Torque - Front Engine Mounting Bolt: 44 №m (4.5 kgf·m 32 ft·lb)
- Run the leads, cables, and hoses correctly (See Cable, Wire, and Hose Routing section in the Appendix chapter).
- Install the removed parts (see appropriate chapters).
Adjust:
- Throttle Cables (See Throttle Control System Inspection in the Periodic Maintenance chapter)
- Clutch Cable (See Clutch Operation Inspection in the Periodic Maintenance chapter)
- Drive Chain (See Drive Chain Slack Adjustment in the Periodic Maintenance chapter)
- Fill the engine with engine oil (See Engine Oil Change in the Periodic Maintenance chapter).
- Fill the engine with coolant and bleed the air from the cooling system (See Coolant Change in the Periodic Maintenance chapter).
- Adjust the idling (See Idle Speed Adjustment in the Periodic Maintenance chapter).
![](https://motoinstruction.ru/img/kawasaki/23/128623.jpg)