![background image](/i/kawasaki/160046/kawasaki-er5-2004/h/kawasaki-er5-2004-095.png)
ENGINE TOP END 4-17
Cylinder Head
•
Install a new cylinder head gasket with "UP" [A] marked
side positioning to the right.
NOTE
○
The camshaft caps are machined with the cylinder head
so if a new cylinder head is installed, use the caps that
are supplied with the new head.
•
Tighten the 10 mm cylinder head bolts following the tight-
ening sequence. Tighten them first to about one half of
the specified torque.
Torque - Cylinder Head Bolts 10 mm: 51 N·m (5.2 kgf·m, 38
ft·lb)
Cylinder Head Bolts 6 mm: 9.8 N·m (1.0 kgf·m, 87
in·lb)
•
Tighten the 6 mm cylinder bolts.
•
Install the camshafts, camshaft caps and top chain guide.
•
Install the head oil pipes.
Cylinder Head Warp
•
Clean the cylinder head (see Cylinder Head Cleaning).
•
Lay a straightedge [A] across the lower surface of the
head at several different points, and measure warp by
inserting a thickness gauge [B] between the straightedge
and the head.
If warp exceeds the service limit, repair the mating sur-
face. Replace the cylinder head if the mating surface is
badly damaged.
Cylinder Head Warp
Service Limit:
0.05 mm (0.002 in.)
Cylinder Head Cleaning
•
Remove the cylinder head (see Cylinder Head Removal).
•
Remove the valves (see Valve Removal).
•
Wash the head with a high-flash point solvent.
•
Scrape [A] the carbon out of the combustion chamber and
exhaust port with a suitable tool.