Cylinder Head Cover Removal
Remove:
- Fuel Tank (See Fuel Tank Removal in the Fuel System (DFI) chapter)
- Air Cleaner Housing (See Air Cleaner Housing Removal in the Fuel System (DFI) chapter)
- Air Suction Valve (See Air Suction Valve Removal)
- Stick Coils (See Stick Coil (Ignition Coil together with Spark Plug Cap) Removal in the Electrical System chapter).
- Throttle Cables [A] (See Throttle Body Assy Removal in the Fuel System (DFI) chapter)
- Inlet Air Pressure Sensor Hose [B]
- Baffle Plate Bolts [C]
- Baffle Plate [D]
- Cylinder Head Cover Bolts [E]
- Clamp [F]
- For models eqquipped with an ABS, open the clamps [G].
For models eqquipped with an ABS, remove the bolt [A] and damper [B].
Remove the cylinder head cover [A] to backward floating it a little up.
Cylinder Head Cover Installation
- Replace the head cover gasket [A] with a new one.
- Apply silicone sealant [B] to the cylinder head as shown.
Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004
- Replace the plug hole gaskets [A] with new ones.
- Be sure to install the following parts.
- Dowel Pins [B]
Plug Hole Gaskets
- Install the rubber washers [A] with metal side faces upward.
Tighten:
Torque - Cylinder Head Cover Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)
- Be sure that the dampers [A] of the baffle plate is in position.
Tighten:
Torque - Baffle Plate Bolts: 5.9 N·m (0.60 kgf·m, 52 in·lb)
