Kawasaki Ninja Service Manual: Valve Installation

Kawasaki Ninja Service Manual / Engine Top End / Valves / Valve Installation

NOTICE

Do not lap the valve to the valve seat, using the grinding compound. It will come off oxide film treated surface of the valve.

Replace the oil seal with a new one.
Apply a thin coat of molybdenum disulfide grease to the valve stem before valve installation.
Install the springs so that the closed coil end faces downwards.

Valve Stem [A] Oil Seal [B] Spring Seat [C] Closed Coil End [D] Valve Spring [E]: EX - Yellow Paint IN - White Paint (∼ ZX100JBF/KBF Early Models) Purple Paint (ZX100JBF/KBF Late Models ∼) Retainer [F] Split Keepers [G]

Valve Installation

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 position ...

Valve Guide Removal

Remove: Valve (see Valve Removal) Oil Seal Spring Seat Heat the area around the valve guide to 120 150°C (248 302°F), and hammer lightly on the valve guide arbor [A] to remove ...

Other materials:

Oil Seal, Grease Seal
Do not remove pressed oil or grease seals unless removal is necessary. Replace with new ones whenever removed. Press new oil seals with manufacture and size marks facing out. Make sure the seal is aligned properly when installing. Apply specified grease to the lip of seal before installing ...

Operational Cautions
1. Do not put two keys of any immobilizer system on the same key ring. 2. Do not submerge any key in water. 3. Do not expose any key to excessively high temperature. 4. Do not place any key close to magnet. 5. Do not place a heavy item on any key. 6. Do not grind any key or alter its ...

Oil Pump Installation
Install the outer rotor [A] into the crankcase. Assemble: Oil (Water) Pump Shaft [B] Pin [C] Inner Rotor [D] To prevent dropping, apply grease to the pin. Install the inner rotor assembly into the crankcase. Fit the slot [E] onto the projection [F]. Replace the O-ring [A ...