bike assembly question

So I'm getting to the point where I'm almost ready to put my motor back in my bike and when I went to check all my labeled bags of bolts and what not I found that the marker I used to write on the bags had mostly worn off and now I'm worried I won't be able to remember where everything goes. I've been looking in my Clymer manual, but it isn't that much help. Is there any photo-tutorial online that anyone knows of that outlines what goes where?
I know I sound like an idiot, so take it easy on me haha

A FSM would probably be more detailed than Clymer.

If not already done, could also pull up the diagrams on kawasaki.com with bolt sizes often shown in the parts listing.

Good Luck!

And here's an example:

[Click on image to enlarge view]






REF NUMBER PART NUMBER DESCRIPTION QUANTITY US CA CN REMARKS


1 92007-031 BOLT,STEERG STEM HEA 1


2 92022-230 WASHER,STEERG STM HD 1


3 46100-003 WASHER,WAVE 1


4 92090-007 NUT STEERING STEM LC 1


5 46098-016 CAP, STEERING STEM 1


6 92047-011 CONE,STRNG STM BRNG 1


7 600A0800 BALL STEEL 1/4' 39


8 92048-006 RACE STRNG STEM BERN 1


9 92048-008 RACE,STRNG STM BRNG 1


10 32002-1010 FRAME 1


11 28012-016 REFLECTOR,REFLEX 2


12 92094-011 DAMPER RUBBER,REFLEC 2


13 92091-022 BOLT,ENGINE MOUNTING 1 L = 310 M/M


14 311B0800 NUT,8MM 2


15 461F0800 WASHER SPRING 8MM 8


16 32030-025 PLATE,ENG MOUNT FRON 1


17 92001-1397 BOLT-8X63 1


18 110G0859 BOLT,HEX HEAD,8X59 1


19 92019-021 NUT,LOCK,10MM 3


20 461F1000 WASHER SPRING 10MM 3


21 92001-1262 BOLT,HEX HEAD,12X55 1


22 115G0818 BOLT-SMALL-UPSET,8X1 2


23 32029-1014 PLATE,FT ENG MNT LWR 1


24 32030-066 PLATE,REAR ENGINE,L. 1


25 32030-067 PLATE,REAR ENGINE,R. 1


26 92001-1578 BOLT 3


27 92027-160 COLLAR,ENG MOUNTING 1 L = 31 M/M


28 92027-159 COLLAR,ENG MOUNTING 1 L = 52 M/M


29 92001-1577 BOLT,FLANGED,8X35 1


30 92003-099 BOLT,ENGINE MOUNTING 1 L = 165 M/M


31 92091-023 BOLT,ENGINE MOUNTING 1 L = 250 M/M


32 92001-1265 BOLT,HEX HEAD,12X70 1


33 461F1200 WASHER SPRING 12MM 2


34 92016-045 NUT,12MM 2


35 32049-101 BRACKET,SIDE COV,R.H 1


36 92037-134 CLAMP,OVER FLOW PIPE 1

Bicycle Lee wrote:

So I'm getting to the point where I'm almost ready to put my motor back in my bike and when I went to check all my labeled bags of bolts and what not I found that the marker I used to write on the bags had mostly worn off and now I'm worried I won't be able to remember where everything goes. I've been looking in my Clymer manual, but it isn't that much help. Is there any photo-tutorial online that anyone knows of that outlines what goes where?
I know I sound like an idiot, so take it easy on me haha

that sucks....figures, you take care and bag and label thinking ahead, and ya get done in by a lousy marker....sounds like my luck....good luck, you ll get em back where they belong just gonna take a little longer......

the long bolts are motor mount bolts!:laugh:

Just do like Plummen does...

Weld the motor into the frame and you won't have to worry about them bolts then... :ohmy: :huh: :dry: :laugh:

i always use the left overs for fishing wheights and wind chimes.....

I think all the bolts only fit in one way. If you have the wrong one in the wrong hole you will know it.

donthekawguy wrote:

I think all the bolts only fit in one way. If you have the wrong one in the wrong hole you will know it.

im not even going there! :ohmy: :huh: :dry: :blink: :S :woohoo: :laugh:

If you grouped them in the bags to the item you were removing it could be easy to figure out. Why not post pictures of them and we can have a contest trying to figure out where they belong.

OKC_Kent wrote:

If you grouped them in the bags to the item you were removing it could be easy to figure out. Why not post pictures of them and we can have a contest trying to figure out where they belong.

Sounds like a plan. I'm test firing the motor tomorrow (fingers and toes crossed), so by this time tomorrow I'll know if I need to bother knowing how to put the thing back in the frame or not.
Thanks to everyone who posted.