I took out the top bolt to see what the 'adjustment collar' was all about, and how it works.
When I did I realized what the manual was talking about and promptly replaced it.
For anyone who hasn't followed the thread closely, the 'adjustment' is between the sides of
the frame and the sides of the engine only, and it is supposed to be 0mm, or no gap at all.
And it only adjusts at the rear, there are no collars at the front, because the ability of the brackets
in the front to bend slightly side to side allow for the gap to be closed without them.
In the back the bolts go through a very rigid part of the frame which is not going to bend easily,
nor is it supposed to.
There is no other provision, either intentionally or otherwise, for the adjustment or movement
of this engine in this frame.
And no, it is not back together yet, but the solution will be posted here when it is.
I think the point everyone is so gingerly trying to make here is did you loosen BOTH rear bolts at the SAME TIME, and allow the back of the engine to move away from the frame? This may in fact let the engine move around just enough that the front will then bolt together.
If it works, you get to put the bolts back in without reaming out the hole. Also, it may be that Kawi is using the engine to align a frame that wasn't built with exacting tolerances, by twisting it with the tightening of the engine bolts. That would explain why they have a "sequence", instead of just "insert and tighten the engine bolts".
If you haven't done this, it would only take a couple of minutes to try, and may save you some other headaches. If you have, just let us know.
Either way, let us know, as I for one will likely be in the same situation if I remove those front mount brackets on mine.