Exploded view
![](https://motoinstruction.ru/img/kawasaki/13/119075.jpg)
No. | Fastener | Torque | Remarks | ||
N·m | kgf·m | ft·lb | |||
1 | Engine Mounting Nuts | 44 | 4.5 | 32 | |
2 | Engine Mounting Bracket Bolts (M10) | 44 | 4.5 | 32 | |
3 | Engine Mounting Bracket Bolts (M8) | 25 | 2.5 | 18 | |
4 | Downtube Mounting Bolts | 44 | 4.5 | 32 |
WL: Apply a soap and water solution.
Special tool
![](https://motoinstruction.ru/img/kawasaki/13/119076.jpg)
Jack: 57001-1238
Engine removal
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)
- Fuel Tank (see Fuel tank removal in the Fuel System (DFI) chapter)
- Muffler (see Muffler removal in the Engine Top End chapter)
- Clutch Cable Lower End (see Clutch cable removal in the Clutch chapter)
- Air Cleaner Housing (see Air cleaner housing removal in the Fuel System (DFI) chapter)
- Throttle Body (see Throttle body removal in the Fuel System (DFI) chapter)
- Regulator/Rectifier (see Regulator/Rectifier Removal in the Electrical System chapter)
- Tool Box (see Tool box removal in the Frame chapter)
- Left Side Cover (see Left side cover removal in the Frame chapter)
- Air Switching Valve (see Air switching valve removal/Installation in the Engine Top End chapter)
- Radiator (see Radiator and radiator fan removal in the Cooling System chapter)
- Engine Pulley (see Engine pulley removal in the Final Drive chapter)
- Front and Rear Shift Lever and Shift Rod (see Shift pedal removal in the Crankshaft/Transmission chapter)
Remove:
- Bolts [A]
- Front Cross Pipe [B]
- Starter Motor Cable [C]
- Oil Pressure Switch Lead [D]
![](https://motoinstruction.ru/img/kawasaki/13/119077.jpg)
Remove:
- Neutral Switch Terminal [A]
![](https://motoinstruction.ru/img/kawasaki/13/119078.jpg)
Remove:
- Speed Sensor Connector [A]
![](https://motoinstruction.ru/img/kawasaki/13/119079.jpg)
Remove:
- Water Temperature sensor Connector [A]
- Water Hoses [B]
- Thermostat Housing Cover Bracket Bolt [C]
![](https://motoinstruction.ru/img/kawasaki/13/119080.jpg)
Remove:
- Cap [A] and Bolt
- Ignition Switch [B]
![](https://motoinstruction.ru/img/kawasaki/13/119081.jpg)
Disconnect:
- Alternator Lead Connector [A]
![](https://motoinstruction.ru/img/kawasaki/13/119082.jpg)
Remove:
- Engine Ground Terminal [A]
![](https://motoinstruction.ru/img/kawasaki/13/119083.jpg)
Support the frame with the jack.
- Special Tool - Jack: 57001-1238
Squeeze the brake lever slowly and hold it with a band [A].
![](https://motoinstruction.ru/img/kawasaki/13/119084.jpg)
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.
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.
Support the engine with a suitable stand.
Remove:
- Downtube [A] (see Downtube removal in the Frame chapter)
- Engine Mounting Bolts [B] and Nuts
- Engine Mounting Brackets [C]
![](https://motoinstruction.ru/img/kawasaki/13/119085.jpg)
Using the stand, take out the engine to the right.
Engine installation
When installing the rubber dampers into the bracket, lubricate the outer surface of the dampers with a soap and water solution.
Caution! Do not lubricate the rubber damper with engine oil or petroleum distillates because they will deteriorate the rubbers.
Support the engine with a suitable stand.
Install the engine mounting bracket and down tube.
Tighten:
- Engine Mounting Bracket Bolts (M8): 25 N·m (2.5 kgf·m, 18.0 ft·lb)
- Engine Mounting Bracket Bolts (M10): 44 N·m (4.5 kgf·m, 32 ft·lb)
- Downtube Bolts: 44 N·m (4.5 kgf·m, 32 ft·lb)
- Engine Mounting Bolts and Nuts: 44 N·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.
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 Belt (see Belt deflection inspection 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).