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:

Tire Air Pressure Inspection
Remove the air valve cap. Measure the tire air pressure with an air pressure gauge [A] when the tires are cold (that is, when the motorcycle has not been ridden more than a mile during the past 3 hours). Install the air valve cap. Adjust the tire air pressure according to the specifi ...

Brakes
Brake Wear Inspection Inspect the brakes for wear. For each front and rear disc brake caliper, if the thickness of either pad is less than 1 mm (0.04 in.), replace both pads in the caliper as a set. Pad replacement should be done by an authorized Kawasaki dealer. A. Lining Thickness B. ...

Camshaft Runout Inspection
Remove the camshafts (see Camshaft Removal). Set the camshaft in a camshaft alignment jig or on V blocks. Measure the runout with a dial gauge at the specified place as shown in the figure. If the runout exceeds the service limit, replace the camshaft. Camshaft Runout Standard: TIR ...