Kawasaki NINJA ZX-12R (2002-2004) [353/613] Engine removal installation 8 5

ENGINE REMOVAL/INSTALLATIO N 8-5

Engine Removal/Installation

Engine Installation

CAUTION

Do not connect the throttle sensor connector to the

inlet air pressure sensor, because the pressure sen-

sor is broken by the opposite electrical connection.

•

Before the engine installing, install the following parts.

Engine Sub Harness [A]

Gear Position Switch Harness [B]

Alternator Leads [D]

•

Confirm:

Cooling Hoses [C] Position

•

Confirm the leads and hoses position as shown.

Clamps [A], [C]

Alternator Lead (Yellow) [B]

Alternator Lead (White) [D]

Gear Position S witch Lead [E]

Engine Sub Harness [F]

Fuel S upply Hose [G]

Tube [H]

Tube [I] (for California Model)

•

Tighten the adjusting collars [A] fully by hand.

Crankcase [B]

•

Support the engine with a suitable s tand.

•

Hang the drive chain over the output shaft just before

moving the engine into its final position in the frame.

•

Insert the lower mounting bolt [A].

•

Set the collar [B] and insert the upper mounting bolt [C].

NOTE

○

Before inserting the engine mounting bolts, verify t hat

the fuel hose and tubes (one tube for California model

only), alternator lead connectors, gear position switch

and engine sub harness connectors are clear an open-

ing between the f rame and engine.