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:

Air Suction Valve Inspection
Remove the air suction valve (see Air Suction Valve Removal). Visually inspect the reeds [A] for cracks, folds, warps, heat damage or other damage. If there is any doubt as to the condition of the reeds, replace the air suction valve as an assembly. Check the reed contact areas [B] of ...

Steering Damper Removal
ZX1000JC/KC Remove: Steering Damper Mounting Bolts (TORX Bolts) [A] Washer [B] Washer and Collar [C] Steering Damper [D] ZX1000JD/KD Remove: Clamp [A] Connector [B] (Disconnect) Steering Damper Mounting Bolts (TORX Bolts) [C] Washer [D] Washer and Collar [E] Elect ...

Stem, Stem Bearing Removal
Remove: Upper Fairing Assembly (see Upper Fairing Assembly Removal in the Frame chapter) Front Fender (see Front Fender Removal in the Frame chapter) Front Wheel (see Front Wheel Removal in the Wheels/Tires chapter) Steering Stem Head with Handlebars (see Handlebar Removal) Fron ...