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:

Meter Unit Circuit (ZX1000J Model)
1. Ignition Switch 2. Joint Connector F 3. Stop Watch Button 4. Oil Pressure Switch 5. Crankshaft Sensor 6. Water Temperature Sensor 7. Gear Position Switch 8. Intake Air Temperature Sensor 9. ESD ECU (ZX1000JD/KD) 10. ECU 11. Rear Wheel Rotation Sensor 12. Engine Ground 13. Battery ...

Front Fork Oil Change
Remove the front fork (see Front Fork Removal (Each Fork Leg)). Turn the spring preload adjuster fully counterclockwise for removing the piston rod assy easily. Hold the inner tube lower end in a vise. Using the wrench [A], unscrew the top plug [B] out of the outer tube. Special Too ...

Intake Air Pressure Sensor #1 Installation
NOTE The intake air pressure sensor #1 is the same part as the intake air pressure sensor #2. Installation is basically the reverse of removal. Position the intake air pressure sensor #1 [A] between the projections [B] on the rubber damper. Install the rubber damper [A] on the bracket ...