Kawasaki Ninja Service Manual: Cylinder Head Removal

Kawasaki Ninja Service Manual / Engine Top End / Cylinder Head / 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 Engine Removal in the Engine Removal/Installation chapter)
Place a container under the coolant drain bolt [B].
Drain the coolant by removing the coolant drain bolt.

Cylinder Head Removal

Remove the front camshaft chain guide bolt (upper) [A].

Cylinder Head Removal

Remove: Front Camshaft Chain Guide Bolt (Lower) [A] Collar Front Camshaft Chain Guide [B] Dowel Pin [C] Rear Camshaft Chain Guide [D]

Cylinder Head Removal

Loosen the M6 and M10 cylinder head bolts as shown sequence [1 12] in the figure,
and remove them with washers.
Remove the cylinder head forward.

Cylinder Head Removal

Cylinder Compression Measurement

NOTE Use the battery which is fully charged. Warm up the engine thoroughly. Stop the engine. Remove the spark plugs (see Spark Plug Replacement in the Periodic Maintenance chapter). Attac ...

Cylinder Head Installation

NOTE 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. Install the dowel pins. Replace the cylinder ...

Other materials:

Nozzle Assy Disassembly
Remove the nozzle assy (see Nozzle Assy Removal). Pull out the secondary fuel injectors [A] from the delivery pipe assy [B]. NOTE Do not damage the insertion portions of the injectors when they are pulled out from the delivery pipe assy. NOTICE Never drop the secondary fuel injecto ...

Stick Coil Removal
Remove the air cleaner housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter). Disconnect the stick coil connectors [A]. Pull out the stick coils [B] upward. First, turn the stick coil by 90 degrees, and then pull it out by twisting the coil head to the left and righ ...

Brake Light Switches
When either the front or rear brake is applied, the brake light goes on. The front brake light switch requires no adjustment, but the rear brake light switch should be adjusted in accordance with the Periodic Maintenance Chart. Inspection Turn the ignition key to “ON”. The brake ligh ...