Kawasaki Ninja Service Manual: Engine Removal

• Support the rear part of the swingarm with a stand.
• Squeeze the brake lever slowly and hold it with a band [A].

NOTICE

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: Upper Fairing Assembly (see Upper Fairing Assembly Removal in the Frame chapter) Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) 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) Clutch Cable Lower End (see Cable Removal in the Clutch 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) Premuffler Chamber (see Premuffler Chamber Removal in the Engine Top End chapter) Shift Lever (see Shift Pedal Removal in the Crankshaft/ Transmission chapter) Engine Sprocket (see Engine Sprocket Removal in the Final Drive chapter)

• Disconnect: Gear Position Switch/Sidestand Switch Lead Connector [A] Crankshaft Sensor/Oil Pressure Switch Lead Connector [B] Stick Coil Connectors (see Stick Coil Removal in the Electrical System chapter)
• Remove the air switching valve (see Air Switching Valve Removal in the Engine Top End chapter).

• Remove the engine ground cable terminal bolt [A].
• Disconnect: Water Temperature Sensor Connector [B] Starter Motor Cable [C] (see Starter Motor Removal in the Electrical System chapter)

• Free the lead from the clamps [A].
• Disconnect the sidestand switch lead connector [B].

• Remove the clamps [A].

• Remove: Bolt [A] Heat Insulation Plate [B] Clear the projections [C] from the frame [D].

• Support the engine with a suitable stand [A].

Put a plank [B] onto the suitable stand for engine balance.

• Remove: Left Front Engine Mounting Bolt [A] Middle Engine Mounting Nut [B] Lower Engine Mounting Nut [C]

• Remove: Right Front Engine Mounting Bolt [A]

• Using the nut wrench [A], loosen the locknut [B].

  Special Tool - Engine Mount Nut Wrench: 57001-1450

• Using the Hexagon Wrench, turn the adjusting collar [A] counterclockwise to make the gap between the engine and adjusting collar.

• Turn the middle and lower engine mounting bolts clockwise to make the gap between the adjusting collar and frame.
• Pull out the engine mounting bolts.
• Using the stand, take out the engine.