Kawasaki Ninja Service Manual: Cylinder Head Cover Installation

• Replace the cylinder head cover gasket [A] with a new one
• Using a high flash-point solvent, clean off any oil or dirt that may be on the silicone sealant coating area. Dry them with a clean cloth.
• Apply silicone sealant [B] to the cylinder head as shown in the figure.

  Sealant - Liquid Gasket, TB1216B: 92104-1064

• Install the new cylinder head cover gasket.

NOTE

Make the application finish within 20 minutes when the liquid gasket (TB1216B) to the mating surface of the cylinder head cover is applied.

• Be sure to install the following parts.

  Dowel Pins [A] Plug Hole Gaskets [B]

• Install the cylinder head cover.
• Install the rubber washers [A] with the metal side faces upward.

• Tighten the cover bolts following the specified tightening sequence.

Torque - Cylinder Head Cover Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)

• Be sure to install the following parts.

  Cover Plug [A] Rubber Cap [B]

• Apply a non-permanent locking agent to the threads of the cylinder head cover plug and tighten it.

Torque - Cylinder Head Cover Plug: 15 N·m (1.5 kgf·m, 11 ft·lb)

• Install the rubber cap so that the flange [C] of it is positioned under the heat insulation rubber plate, and cover the boss of head cover and cover bolt.
• Install the removed parts (see appropriate chapters).