Kawasaki Ninja Service Manual: Cylinder Head Cover Installation

Kawasaki Ninja Service Manual / Engine Top End / Cylinder Head Cover / 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.

Cylinder Head Cover Installation

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]

Cylinder Head Cover Installation

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

Cylinder Head Cover Installation

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)

Cylinder Head Cover Installation

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).

Cylinder Head Cover Installation

Cylinder Head Cover Removal

Remove: Air Suction Valves (see Air Suction Valve Removal) Throttle Body Assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter) Stick Coils (see Stick Coil Removal in the El ...

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Special Tools
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Fuse Inspection
Remove the fuse. Inspect the fuse element. If it is blown out, replace the fuse. Before replacing a blown fuse, always check the amperage in the affected circuit. If the amperage is equal to or greater than the fuse rating, check the wiring and related components for a short circuit. ...

Kawasaki Ninja Service Manual: Cylinder Head Cover Installation

Cylinder Head Cover Removal

Camshaft Chain Tensioner

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