Kawasaki Z400 - Service manual > Engine Removal/Installation

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R: Replacement Parts

S: Follow the specified tightening sequence

Engine Removal/Installation

Engine Removal

• Support the front and rear of the motorcycle with the stands

NOTICE

Be sure to use the front and rear stands when removing the engine, or the motorcycle may fall over.

The engine or the motorcycle could be damaged.

• Drain: Engine 011 (see Engine Oil Change in the Periodic Main- - chap*) Coolant (see Coolant Change in the Periodic Maintenance chapter)
• Remove: Middle Fairings (see Middle Fairing Removal in the Frame 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) Radiator (see Radiator Removal in the Cooling System chapter Exhaust Pipe (see Exhaust Pipe Removal in the Engine Top End chapter) Right Frame Cover (see Frame Cover Removal in the Frame chapter) Shift Lever (see Shift Pedal Removal in the Crankshaft/Transmission chapter) Engine Sprocket (see Engine Sprocket Removal in the Final Drive chapter) Clutch Cable Ends (see Clutch Cable Removal in the Clutch chapter) Air Switching Valve (see Air Switching Valve Removal in the Engine Top End chapter) Gear Position Sensor (see Gear Position Sensor Re- .m oval in the Electrical System chapter)
• Disconnect: Oil Pressure Switch Lead (see Oil Pressure Switch Removal in the Engine Lubrication System chapter) Stick Coil Connectors (Stick Coil Removal in the Electrical System chapter) Alternator Connector (see Alternator Cover Removal in the Electrical System chapter) Crankshaft Sensor Connector (see Crankshaft Sensor Removal in the Electrical System chapter) Starter Motor Cable (see Starter Motor Removal in the Electrical System chapter) Water Temperature Sew Connector (see Water Temperature Sensor Removal/Installation in the Fuel System (DFI) chapter)
• Remove: Fame Bracket Bolts [A] (Both Sides) Fame Bracket [B] (Both Sides

• Slide the cap [A] and disconnect the engine ground lead.

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

  Put planks [B] onto the stand for engine balance.

Loosen: Swingarm Mounting Plate Bolt [A] and Nut Swingarm  Pivot Shaft Nut [B] Lower Swingarm Side Bracket Bolt [C] (Both Sides)

Remove: Front Engine Mounting Bolt [A] (Both Sides) Middle Engine Mounting Bolt [B] (Both Sides) Collars (Left Side)

• Remove:

Rear Engine Mounting Bolts [A]

Dowel Pins [B]

Engine [C]

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Engine Installation

• Replace the swingarm mounting plate nut with a new one.
• Support the front and rear of the motorcycle with the stands.
• Support the engine with a suitable stand.

Put planks onto the stand for engine balance.

• Install the dowel pins [A].

• Install the engine to the swingarm mounting plate [A].
• Install all bolts and collars [B] and tighten them temporarily in the following order.

Rear Engine Mounting Bolts

Right Front Engine Mounting Bolt

Left Front Engine Mounting Bolt

Right Middle Engine Mounting Bolt

Left Middle Engine Mounting Bolt

• Tighten the bolts and nuts to the specified toque in the specified sequence.

Toque - Rear Engine Mounting Bolts [1 - 41: 44 N-m (4.5 kgf-m, 32 ft-lb)

Front Engine Mounting Bob [S - 61: 44 N-m (4.5 kgf-m, 32 ft-lb)

Middle Engine Mounting Bolts 17 - 81: 44 Nm (4.5 kgf-m, 32 ft*lb)

Swingarm Mounting Plate Nut p]: 44 N-m (4.5 kgf*m, 32 ft*lb)

Swingarm Pivot Shaft Nut [lq: 10% N-m (11.0 kgf*m, 79.7 ft*lb)

Lower Swingarm Sick Bracket Bolts [11]: 34 Nm (3.5 kgf*m, 25 ft-lb)

Upper Swingarm Side Bracket Bolts [12]: 20 Nm (2.0 kgf*m, 15 ft-lb)

• Install the frame brackets and tighten the frame bracket bolts.

Tighten the front side bolt first

Torque - Frame Bracket Bob: 34 N-m (3.5 kgf-m, 25 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) Drive Chain (see Drive Chain Slack 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 (see Coolant Change in the Periodic Maintenance chapter).

Swingarm Mounting Plate Removal

Remove: Engine (see Engine Removal) Side Stand (see Side Stand Removal in the Frame chapter) Tie-Rod and Rocker Arm (see Tie-Rod Removal in the Suspension chapter) Swingarm (see Swingarm Removal in the Suspension chapter)

Remove: Bolt [A] and Clamp [B] Rear Shock Absorber Bracket Bolts and Nuts [C] Lower Swingarm Side Bracket Bolt [D] (Both Sides) Swingarm Mounting Plate Bolt [E] and Nut Swingarm Mounting Plate [F]

• Remove: Side Stand Bracket Bolts [A] Side Stand Bracket [B]

Swingarm Mounting Plate Installation

• Install: Side Stand Bracket [A]
• Tighten:

Toque -Side Stand Bracket Bolts [B]: 49 Nm (5.0 kgf-m, 36 R4b

• Tighten the rear bolt first.

  Front [C] Rear [D]

• Install the swingarm mounting plate, and tighten its bob and nub temporarily.
• Install the swingarm (see Swingarm Installation in the Suspension chapter).

Tighten the swingarm pivot shaft nut temporarily

• Install the removed parts (see appropriate chapters).

See also: