Engine Removal / Installation
Lifting the 2 053 cm³ V-twin out of the frame and refitting it: the front-brake-hold safety rule, the strip-down list, and the 12-step mount/downtube tightening sequence (front downtube 88 N·m → rear downtube 108 N·m).
Chapters· Engine Removal / Installation
Source: Service Manual — pp. 8-1 … 8-11src: Kawasaki VN2000-A1 Service Manual — Periodic Maintenance (Torque & Locking Agent / Specifications tables, pp. 2-7…2-13)
Tools the job needs
| Jack | 57001-1238 |
|---|---|
| Jack Attachment | 57001-1571 |
| Socket Wrench (adjuster locknuts) | 57001-1347 |
The engine is a stressed member: the two downtubes and the engine itself tie the front and rear of the frame together. Support the frame on the jack and a commercial engine stand before any mount fastener comes out, and never work under an unsupported engine.src: Kawasaki VN2000-A1 Service Manual — Periodic Maintenance (Torque & Locking Agent / Specifications tables, pp. 2-7…2-13)
Every mount fastener is tightened in the numbered order 1→12; three are tightened alternately in two passes.
Engine-mount tightening sequence
| # | Fastener | Torque | Remarks |
|---|---|---|---|
| 1 | Front downtube nuts | 88 N·m | S, AL |
| 2 | Upper adjusting bolt | 9.8 N·m | S |
| 3 | Lower adjusting bolt | 9.8 N·m | S |
| 4 | Upper adjusting-bolt locknut | 49 N·m | S |
| 5 | Lower adjusting-bolt locknut | 49 N·m | S |
| 6 | Upper rear engine mounting nut | 59 N·m | S |
| 7 | Lower rear engine mounting nut | 59 N·m | S |
| 8 | Upper engine bracket nuts | 59 N·m | S, AL |
| 9 | Upper engine mounting bolts | 44 N·m | S |
| 10 | Lower engine bracket bolts | 59 N·m | S |
| 11 | Front engine mounting nut | 44 N·m | S |
| 12 | Rear downtube bolts | 108 N·m | S, AL |
S = tighten strictly in this 1→12 sequence · AL = tighten the pair alternately, two passes, for even torque (front downtube nuts 1, upper bracket nuts 8, rear downtube bolts 12).
Support the frame, hold the front brake, strip the services, then drop the downtubes and lift the engine out the right side.
Be sure to hold the front brake when removing the engine, or the motorcycle may fall over — it could cause an accident and injury. Squeeze the front brake lever and hold it with a band before lifting on the jack.src: Kawasaki VN2000-A1 Service Manual — Periodic Maintenance (Torque & Locking Agent / Specifications tables, pp. 2-7…2-13)
Engine removal
Support the rear of the frame on the jack (57001-1238) and the attachment (57001-1571) and steady the engine on a commercial stand.
Jack 57001-1238 · Jack Attachment 57001-1571 · Socket Wrench 57001-1347
- 1
Squeeze the front brake lever and hold it with a band, then support the frame on the jack and attachment.
- 2
Drain the coolant (see Cooling System) and the engine oil (see Engine Lubrication).
- 3
Remove the battery cables, fuel tank and air-cleaner housings (Fuel/DFI), the air-switching valve with hoses and the exhaust pipes & mufflers (Engine Top End), the clutch cable (Clutch), the engine pulley (Final Drive), the shift pedals & rod (this chapter), and the radiator & thermostat (Cooling); disconnect the throttle-cable upper ends.
- 4
Disconnect the inlet-air-pressure-sensor hoses, the vacuum hose and the subharness connector, then remove the spark-plug caps, the ignition-coil bracket and the engine brackets.
- 5
Disconnect every engine lead: alternator, crankshaft sensor, side-stand switch, oil-pressure switch, speed sensor, gear-position sensor, compression-release solenoid, horn, rear-brake switch and the regulator/rectifier; undo the Allen bolt and free the starter-motor lead terminal; remove the engine ground terminal and the hose cover.
- 6
Support the engine with a commercial stand. Remove the front engine mounting bolt & nut and the downtube bolts & nuts, then the downtubes (both sides).
Remove the right downtube with the right footboard, regulator/rectifier and rear master cylinder still attached.
- 7
Remove the radiator-hose pipe, move the owner’s tool box aside, and remove the rear engine mounting bolts & nuts.
- 8
Unscrew the upper and lower adjuster locknuts with the socket wrench (57001-1347), then back the adjusters out to open a gap between the engine and frame.
This frees the engine without forcing it.
- 9
Move the engine forward a little, disconnect the canister-purge / reserve-tank / fuel-tank-breather / fuel-return / vacuum hoses as fitted, then lift the engine out of the frame from the right side.
Torque the twelve fasteners in sequence, zero the adjusting-bolt clearance, then refill and bed the brakes before riding.
Engine installation
Support the engine on a stand and offer it in from the right. Set the rear-mount collar and insert the lower rear mounting bolt first.
- 1
Torque every mount fastener in the numbered sequence 1→12 (see the table above).
Torquefront DT 88 · adjusters 9.8 · locknuts 49 · rear mounts 59 · upper brackets 59 · upper mount bolts 44 · lower brackets 59 · front mount 44 · rear DT 108 N·mTighten the front downtube nuts (1), upper engine bracket nuts (8) and rear downtube bolts (12) alternately in two passes for even torque.
- 2
Set the adjusting bolts (upper and lower) so the clearance between the bolt heads and the crankcase is exactly 0 mm, then torque the adjusting-bolt locknuts with the socket wrench (57001-1347).
Torqueadjusting bolt 9.8 · locknut 49 N·m - 3
Run the leads, cables and hoses correctly (see Cable, Wire & Hose Routing in the Appendix), then refit all removed parts and adjust the throttle cables (Fuel/DFI).
- 4
Fill the engine with oil and refill & bleed the cooling system (Periodic Maintenance), then adjust the idle speed and the drive belt (Periodic Maintenance) and check clutch operation.
- 5
Pump the brake lever and pedal until firm before moving the bike.
WarningDo not ride until a full, firm lever and pedal is obtained by pumping the brakes until the pads are against the discs — the brakes will not work on the first application if this is skipped.
- Frame →The downtubes and engine brackets these fasteners join.
- Crankshaft / Transmission →Splitting the crankcase once the engine is out.
- Periodic Maintenance →Oil & coolant refill, idle and drive-belt adjustment after install.
- Cooling System →Coolant drain & bleed around engine R&I.