Kawasaki Z1000SX - Service manual > 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.

• Replace the cylinder head gasket [A] with a new one.
• Install the dowel pins [B] and cylinder head gasket.

• Replace the cylinder head bolt washers [A] with new ones.
• Apply molybdenum disulfide oil solution to both sides [B] of the cylinder head bolt washers and threads [C] of the bolts.

• Tighten the M10 cylinder head bolts following the tightening sequence [1 - 10].

  Torque - Cylinder Head Bolts (M10):
   First 20 N*m (2.0 kgf*m, 15 ft*lb)
   Final 54 N*m (5.5 kgf*m, 40 ft*lb)

• Tighten:
  Torque -
   Cylinder Head Bolts (M6) [A]: 12 N*m (1.2 kgf*m, 106 in*lb)
   Upper Adjusting Collar: 9.8 N*m (1.0 kgf*m, 87 in*lb)
   Upper Adjusting Collar Locknut: 4.9 N*m (5.0 kgf*m, 36 ft*lb)
   Upper Engine Mounting Bolts: 44 N*m (4.5 kgf*m, 32 ft*lb)
   Lower Engine Bracket Bolts: 59 N*m (6.0 kgf*m, 44 ft*lb)

• Install:
  Front Camshaft Chain Guide [A]
  Rear Camshaft Chain Guide [B]
  New O-rings [C]
  Collar [D]
  • Apply grease to the new O-ring.
• Tighten:
  Torque -
   Front Camshaft Chain Guide Bolt (Upper) [E]: 25 N*m (2.5 kgf*m, 18 ft*lb)
   Front Camshaft Chain Guide Bolt (Lower) [F]: 12 N*m (1.2 kgf*m, 106 in*lb)
   Rear Camshaft Chain Guide Bolt [G]: 25 N*m (2.5 kgf*m, 18 ft*lb)
• Install the removed parts (see appropriate chapters).

Cylinder Head Warp Inspection

• Clean the cylinder head.
• Lay a straightedge across the lower surface of the cylinder head at several positions.
• Use a thickness gauge [A] to measure the space between the straightedge [B] and the head.

Cylinder Head Warp
 Standard: - - -
 Service Limit: 0.05 mm (0.002 in.)

If the cylinder head is warped more than the service limit, replace it.

If the cylinder head is warped less than the service limit, repair the head by rubbing the lower surface on emery paper secured to a surface plate (first No. 200, then No.400).

See also: