SHIPPING YOUR ENGINE TO US

This page will guide you through the Kawasaki FJ/FE/KF series engine removal process and breaking down the engine for shipping. The process is simple if you have the time and the right tools. Below is a checklist to follow before packing and shipping your engine.

Disconnect the battery cables (negative first) and remove the battery.
Drain the engine oil by removing the oil drain plug. Make sure it drains completely and reinstall the drain plug. Do NOT remove the oil filter.
Remove the drive belt (by rolling the belt off the rear clutch by hand).
Remove the exhaust system. Retain the exhaust gasket for reuse.
Disconnect throttle cable on carburetor.
Disconnect the fuel line on the carburetor.
Remove the entire carburetor assembly from the threaded studs.
Disconnect the fuel line to the crankcase vent tube on the engine.
Disconnect the wiring on the Starter generator (there are 3 connections, do not remove the green jumper wire on the generator).
Remove the Starter generator from the bracket holding it to the top of the engine.
Disconnect the yellow wire from at the low oil pressure switch on the lower back of the engine block by removing the bullet connector.
Disconnect the black/white wire from the RPM Limiter by disconnecting the bullet connector on the black wire leading to the RPM Limiter.
Disconnect the ground wire from the oil filler tube mount.
Disconnect the governor cable from the transaxle by removing the spring from the transaxle bracket, then pull it forward through the two straps.
Remove the four 8 MM bottom engine mounting bolts, nuts, and washers.
Remove the two rear engine mounting flange nuts.
Slide engine forward and remove the two spacers from the pan.
Slide the engine forward and remove it through the seat opening. Place engine securely on a table or workbench.

Once the engine is out of the cart and on a table, there is more disassembly to be done before it can be shipped:

Remove the four metal engine covers from around the engine.
Unplug the spark plug wire and remove the spark plug.
Disconnect the coil ground wire from the coil and magnet assembly.
Remove the coil ground wire from the engine clip.
Remove the spark plug wire, coil and magnet assembly.
Remove the RPM limiter and bracket.
Remove the oil filler tube dipstick assembly by twisting and pulling it out.
Remove the two 8mm threaded studs protruding from the rear of the engine - NOTE: these have been loc-tite into place.
Remove the two 6mm threaded carburetor studs protruding from the cylinder head
Remove the Starter generator bracket from the top of the engine.
Remove the front clutch by first removing the retaining bolt.
NOTE: The direction for removing the bolt is different for CW and CCW engines. For CW engines, the bolt is LEFT hand thread; for CCW engines the bolt is RIGHT hand thread.
Next, generously soak the inside of clutch retaining bolt hole with Liquid Wrench oil and let soak for 4 hours. Then using a Club Car clutch puller tool, (you may have to buy the tool or borrow it from a CC dealer) remove the clutch from the crankshaft by first coating the threads on the puller tool with oil or anti-seize grease, then hand tighten the puller in and out of the clutch two times. Once threads of puller turn freely in the clutch by hand, then use an impact wrench to remove the clutch.
Remove the starter generator adjustment/tension bracket from the side of the engine.
Remove the two wire loom retainer straps from the engine and place them with the governor cable.
NOTE: For Kawasaki FE 290cc, 350cc and 400cc engines only, it is optional to remove the flywheel from the engine. Removing the flywheel will save shipping costs and mitigate damage during shipping. This does NOT apply for Yamaha engines. For all Yamaha rebuilds, the flywheel is required.

You are now ready to ship your engine. Use a 12” x 12” x 16” heavy duty cardboard moving box from Lowes. Place the engine in the box and add Styrofoam or cardboard around the engine on both sides of crankshaft to prevent shifting and damage during shipment. The box should weigh around 48 pounds. For packing and shipping of KF 82 Flat head engines please call for suggested process. Go to UPS and ship the engine to me:

Vic Auito
1239 Channel Park SW
Marietta, GA 30064

ATTENTION YAMAHA, KAWASAKI, SUBURU and KOHLER ENGINE OWNERS: Honest Injun expects to receive a Long-Block-Configuration from the owner, which is an engine with all the ancillary components removed prior to shipment. An owner can ship the engine complete and request all components be cross-decked onto the new engine core for a cost minimum of $100. Please note, if an engine is received with components attached they will be shipped back to the owner with the new engine.

Upon arrival, I will disassemble and inspect the engine for what is required. The basic rebuild includes everything that is designed to wear (rings, piston, seals, gaskets, rebuilding the head, complete inspection and cleaning & coating with surface treatment to facilitate cleaning, measuring connecting rods, margin requirements, crankshaft) I will rebuild the engine and send you the test-break-in VIDEO of your engine with your ID marked on the engine case.

See the “Services” page for the rebuild cost. I will send a Venmo payment request using the Friends and Family payment method only for the rebuild plus $30 for packing and shipping charges. When the Venmo funds have arrived, I will ship the rebuilt engine to the owner within one hour and text you a photo of the UPS Tracking number. Please note that any return shipping damage is not covered under the engine warranty and owner assumes all risks of damage caused by shipper.

ENGINE WARRANTY POLICY:

Please note, these are the requirements for the warranty:

New Carburetor
High Mileage Conventional 10w30 NON-Synthetic motor oil
Minimum 89 Octane NON-Ethanol fuel
RPM Rev Limiter must be installed
Throttle governors set within limits

Thank you for your business!