Kawasaki Ninja Service Manual: Cylinder Head Installation

Kawasaki Ninja Service Manual / Engine Top End / Cylinder Head / Cylinder Head Installation


The camshaft cap is machined with the cylinder head, so if a new cylinder head is installed, use the cap that is supplied with the new head.

Cylinder Head Installation

Torque - Cylinder Head Bolts (M10): First: 20 N·m (2.0 kgf·m, 15 ft·lb) Final: 45 N·m (4.6 kgf·m, 33 ft·lb)

Torque - Cylinder Head Bolts (M6): 12 N·m (1.2 kgf·m, 106 in·lb)

Cylinder Head Installation

Torque - Front Camshaft Chain Guide Bolt (Upper) [F]: 25 N·m (2.5 kgf·m, 18 ft·lb) Front Camshaft Chain Guide Bolt (Lower) [G]: 12 N·m (1.2 kgf·m, 106 in·lb)

Cylinder Head Installation

Cylinder Head Removal
Remove: Thermostat Housing (see Thermostat Removal in the Cooling System chapter) Exhaust Pipe (see Exhaust Pipe Removal) Camshafts (see Camshaft Removal) Heat Insulation Plate [A] (see E ...

Cylinder Head Warp Inspection
Clean the cylinder head. Lay a straightedge across the lower surface of the cylinder head at several positions. Use a thickness gauge [A] to measure the space between the straightedge [B] a ...

Other materials:

Valve Removal
Remove the cylinder head (see Cylinder Head Removal). Remove the valve lifter and shim. Mark and record the valve lifter and shim locations so they can be installed in their original positions. Using the valve spring compressor assembly, remove the valve. Special Tools - Valve ...

DFI System Troubleshooting Guide
NOTE This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties in DFI system. The ECU may be involved in the DFI electrical and ignition system tro ...

Crankcase Splitting
Remove the engine (see Engine Removal in the Engine Removal/Installation chapter). Set the engine on a clean surface and hold the engine steady while parts are being removed. Remove: Cylinder Head (see Cylinder Head Removal in the Engine Top End chapter) Starter Motor (see Starter M ...