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:

Camshaft Removal
Remove: Cylinder Head Cover (see Cylinder Head Cover Removal) Crankshaft Sensor Cover (see Crankshaft Sensor Removal in the Electrical System chapter) Using a wrench on the timing rotor bolt [A], turn the crankshaft clockwise until the line [B] (TDC mark for #1,4 pistons) on the timin ...

Special Tools and Sealant
Oil Pressure Gauge, 5 kgf/cm²: 57001-125 Hand Tester: 57001-1394 Needle Adapter Set: 57001-1457 Extension Tube: 57001-1578 Fuel Pressure Gauge Adapter: 57001-1593 Fuel Hose: 57001-1607 Measuring Adapter: 57001-1700 Liquid Gasket, TB1211: 56019-120 ...

Gear Position Switch Removal
Remove: Oil Pump (see Oil pump Removal in the Engine Lubrication System chapter) Engine Sprocket (see Engine Sprocket Removal in the Final Drive chapter) Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Disconnect the connector [A]. Remove: Screws [A] ...