Kawasaki Z1000 - ZR1000 2003-04 Service Manual - Small Engine ...

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5-20 ENGINE TOP END
Cylinder Head
Cylinder Head Removal
Drain the coolant (see Cooling System chapter).
• Remove:
Exhaust Pipes (see Exhaust Pipe Removal)
Coolant Drain Bolt [A] (cylinder)
• Remove:
Cylinder Head Cover (see Cylinder Head Cover Removal)
Camshaft Position Sensor (see Electrical System chapter)
Camshafts (see Camshaft Removal)
Throttle Body (see Fuel System (DFI) chapter)
Water Hose [A]
Bracket Bolt [B]
Engine Bracket [C]
Cam Chain Guide
• Remove the M6 cylinder head bolts [B], and then the M10
cylinder head bolts [A].
• Take off the cylinder head.
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 a new cylinder head gasket and dowel pins.
• Apply molybdenum disulfide oil solution to both sides [A]
of the cylinder head bolt washers [B] and the thread of
head bolts [C].
• 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, 14.5 ft·lb)
Final Used Bolts 49 N·m (5.0 kgf·m, 36 ft·lb)
New Bolts 54 N·m (5.5 kgf·m, 40 ft·lb)
• Tighten the M6 cylinder head bolts [11 ∼ 12].
Torque - Cylinder Head Bolts (M6): 12 N·m (1.2 kgf·m, 104
in·lb)