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Engine Installation - Kawasaki KDX200 Service Manual

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6·4 ENGINE
REMOVAL/
INSTALLATION
i,.WARNING
The
swlngarm
pivot
shaft also
serves
as the engine
mountlnb
boll.
reke precautlonllo insure the
frame is well supported, and thai
the
motorcycle will not lall over
when the
pivot
shaft Is
removed
.
Pull
out
the
5wingarm pivot shah [AJ
.
Remove th
engine
brackets
[8] and
the
engine mounting bolts
[C]
.
Twist the
engine clockwise and
remove the
engine from the vehicle's
right
side.
Eng;ne
Installation
eTlghten
the
following fasteners in the order lisled.
Torque
-
Swlngarm Pivot Nut: 88
N·m
(9.0 kg-m, 65 ft-Ib)
10 mm Engine Mountrng Bolts
and Nuts:
.
Install:
44 N-m
(4.5
kg-m,
33
ft-Ib)
8
mm Engine Mounting Bolts
and Nuts:
29 N-m
(3.0 kg-m, 22
tt.
lb)
Engine Sprocket
Run the
cables, hoses, and leads according
to
the
Cable, Wire,
and
Hose Routing
section in
the
General Information
chapter.
elnstall the
parts removed
(see
the
appropriate chapters).
eAdjust:
Throttle Cable
(see
Fuel
System chapter)
Clutch
(see
Clutch
chapter)
Drive
Chain (see Final
Drive
chapter)
e
Fill
the
engine with transmission oil (see CrankshaftfTransmission
chapter)
.
e
Fill the
engine with coolant and bleed the air from the cooling system
(see Cooling System chapter)
.
eAdjust
the
throttle cable.
e
Adjust the throttle stop
screw.
e
Check
the brake
effectiveness.
~
.. WARNING
Do not
attempt
to ride ttle motorcycle until
a
tull
brake taver or pedal
..
obtained by pumping ttle brake lever
or pedal until
ttle
pads
are
agalmt
ttle disc.
The
brake
wilt
not
tuncUon
on
ttle nrst application
of the
taver
or pedal" ttl.
Is
not
done.

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   Also See for Kawasaki KDX200

This manual is also suitable for:

Kdx220 1995-2006

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