ENGINE TOP END 5-5
Exploded View
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No. |
Fastener |
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Torque |
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Remarks |
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N·m |
kgf·m |
ft·lb |
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1 |
Coolant drain plug (cylinder) |
9.8 |
1.0 |
87 in·lb |
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2 |
Exhaust pipe manifold holder nuts |
17 |
1.7 |
12 |
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3 |
Muffler body clamp bolt |
17 |
1.7 |
12 |
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4 |
Muffler body mounting bolt |
30 |
3.0 |
22 |
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5 |
Crankshaft sensor cover bolts |
11 |
1.1 |
95 in·lb |
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6."1T" marked side faces up.
7."2T" marked side faces up.
8.Hollow mark faces forward. EO: Apply engine oil.
R: Replacement Parts
Exhaust System
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UK: U.K. Model |
78.2: |
Horsepower 78.2 kW (106.3 ps) |
Full: Full Power |
H: |
Honeycomb Type Catalyst |
5-6 ENGINE TOP END
Specifications
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Item |
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Standard |
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Service Limit |
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Clean Air System: |
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Vacuum switch valve closing |
Open → Close |
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– – – |
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pressure |
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41 |
49 kPa (310 370 mmHg, 6.0 7.1 |
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psi) |
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Camshafts: |
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Cam height: |
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Exhaust |
36.146 |
36.254 mm (1.4231 |
1.4273 in.) |
36.05 mm (1.419 in.) |
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Inlet |
36.746 |
36.854 mm (1.4467 |
1.4509 in.) |
36.65 mm (1.443 in.) |
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Camshaft journal, camshaft |
0.028 |
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0.071 mm (0.0011 |
0.0028 in.) |
0.16 mm (0.0063 in.) |
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cap clearance |
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Camshaft journal diameter |
23.950 |
23.972 mm (0.9429 |
0.9438 in.) |
23.92 mm (0.942 in.) |
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Camshaft bearing inside |
24.000 |
24.021 mm (0.9449 |
0.9457 in.) |
24.08 mm (0.948 in.) |
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diameter |
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Camshaft runout |
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TIR 0.02 mm (0.0008 in.) or less |
TIR 0.1 mm (0.004 in.) |
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Cylinder Head: |
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Cylinder compression |
(usable range) |
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1 110 |
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1 590 kPa (11.3 |
16.2 kgf/cm², |
– – – |
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161 |
230 psi) @300 r/min (rpm) |
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Cylinder head warp |
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– – – |
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0.05 mm (0.002 in.) |
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Valves: |
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Valve clearance: |
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Exhaust |
0.22 |
0.31 mm (0.0087 |
0.0122 in.) |
– – – |
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Inlet |
0.15 |
0.24 mm (0.0059 |
0.0094 in.) |
– – – |
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Valve head thickness: |
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Exhaust |
1.0 mm (0.039 in.) |
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0.5 mm (0.020 in.) |
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Inlet |
0.5 mm (0.020 in.) |
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0.25 mm (0.0098 in.) |
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Valve stem bend |
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TIR 0.01 mm (0.0004 in.) or less |
TIR 0.05 mm |
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(0.002 in.) |
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Valve stem diameter: |
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Exhaust |
3.955 |
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3.970 mm (0.1557 |
0.1563 in.) |
3.94 mm (0.155 in.) |
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Inlet |
3.975 |
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3.990 mm (0.1565 |
0.1571 in.) |
3.96 mm (0.156 in.) |
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Valve guide inside diameter: |
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Exhaust |
4.000 |
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4.012 mm (0.1575 |
0.1580 in.) |
4.08 mm (0.161 in.) |
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Inlet |
4.000 |
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4.012 mm (0.1575 |
0.1580 in.) |
4.08 mm (0.161 in.) |
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Valve/valve guide clearance |
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(wobble method): |
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Exhaust |
0.09 |
0.18 mm (0.0035 |
0.0071 in.) |
0.40 mm (0.016 in.) |
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Inlet |
0.03 |
0.12 mm (0.0012 |
0.0047 in.) |
0.33 mm (0.013 in.) |
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Valve seat cutting angle |
45°, 32°, 60° |
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– – – |
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Valve seating surface: |
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Width: |
Exhaust |
0.5 |
1.0 mm (0.020 |
0.039 in.) |
– – – |
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Inlet |
0.5 |
1.0 mm (0.020 |
0.039 in.) |
– – – |
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Outside diameter: |
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Exhaust |
21.6 |
21.8 mm (0.850 0.858 in.) |
– – – |
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Inlet |
26.4 |
26.6 mm (1.0276 |
1.0472 in.) |
– – – |
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ENGINE TOP END 5-7 |
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Specifications |
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Item |
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Standard |
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Service Limit |
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Valve spring free length: |
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Exhaust |
40.7 mm (1.602 in.) |
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38.9 mm (1.531 in.) |
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Inlet |
40.7 mm (1.602 in.) |
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38.9 mm (1.531 in.) |
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Cylinder, Pistons: |
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Cylinder inside diameter: |
68.400 |
68.412 mm (2.6929 |
2.6934 in.) |
68.50 mm (2.6969 in.) |
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Piston diameter |
68.345 |
68.360 mm (2.6907 |
2.6913 in.) |
68.21 mm (2.6854 in.) |
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Piston/cylinder clearance |
0.040 |
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0.067 mm (0.0016 0.0026 in.) |
– – – |
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Piston ring/groove |
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clearance: |
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Top |
0.04 |
0.08 mm (0.0016 |
0.0031 in.) |
0.18 mm (0.0071 in.) |
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Second |
0.02 |
0.06 mm (0.0008 |
0.0024 in.) |
0.16 mm (0.0063 in.) |
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Piston ring groove width: |
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Top |
0.83 |
0.85 mm (0.0327 |
0.0335 in.) |
0.93 mm (0.037 in.) |
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Second |
0.81 |
0.83 mm (0.0319 |
0.0327 in.) |
0.91 mm (0.036 in.) |
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Piston ring thickness: |
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Top |
0.77 |
0.79 mm (0.0303 |
0.0311 in.) |
0.70 mm (0.028 in.) |
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Second |
0.77 |
0.79 mm (0.0303 |
0.0311 in.) |
0.70 mm (0.028 in.) |
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Piston ring end gap: |
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Top |
0.30 |
0.40 mm (0.0118 |
0.0157 in.) |
0.7 mm (0.028 in.) |
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Second |
0.45 |
0.55 mm (0.0177 |
0.0217 in.) |
0.8 mm (0.031 in.) |
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5-8 ENGINE TOP END
Special Tools and Sealant
Compression Gauge: |
Valve Seat Cutter, 32° - |
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25: |
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57001–221 |
57001–1118 |
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Valve Spring Compressor Assembly: 57001–241
Valve Seat Cutter, 32° - 28: 57001–1119
Piston Pin Puller Assembly: 57001–910
Valve Seat Cutter Holder Bar: 57001–1128
Valve Seat Cutter, 45° - 24: 57001–1113
Valve Spring Compressor Adapter, 20: 57001–1154
Valve Seat Cutter, 45° - 27.5: |
Valve Guide Arbor, 4: |
57001–1114 |
57001–1273 |
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ENGINE TOP END 5-9 |
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Special Tools and Sealant |
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Valve Guide Reamer, |
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4: |
Valve Seat Cutter, 60° - |
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25: |
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57001–1274 |
57001–1328 |
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Valve Seat Cutter Holder, 4: 57001–1275
Valve Seat Cutter, 60° - 27: 57001–1409
Fork Oil Level Gauge: 57001–1290
Spark Plug Wrench (Owner’s Tool): 92110–1146
Compression Gauge Adapter, M10 × 1.0: |
Kawasaki Bond (Silicone Sealant): |
57001–1317 |
56019–120 |
5-10 ENGINE TOP END
Clean Air System
Air• Suction Valve Removal
Remove:
Fuel Tank (see Fuel System (DFI) chapter)
Connector [A] (from Clamp [B])
Air Suction Valve Cover Bolts [C] and Clamp Air Suction Valve Cover [D]
Air Suction Valve
Air• Suction Valve Installation
Install the air suction valve [A] so that its wider side [B] of
•the reed valve case faces the front. Tighten:
Torque - Air Suction Valve Cover Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)
Air• Suction Valve Inspection
Refer to the Engine Top End in the Periodic Maintenance chapter.
Vacuum• Switch Valve Removal
Remove:
Fuel Tank (see Fuel System (DFI) chapter)
Vacuum Switch Valve [A]
Vacuum• Switch Valve Installation
Install the vacuum switch valve so that the vacuum fitting
•[A] faces left side.
Route the hoses correctly (see Appendix chapter).
ENGINE TOP END 5-11
Clean Air System
Vacuum• Switch Valve Test
Remove:
Vacuum Switch Valve (see Vacuum Switch Valve Re-
• moval)
Connect a vacuum gauge [A] and syringe [B] or fork oil level gauge to the vacuum hoses as shown.
Special Tool - Fork Oil Level Gauge: 57001–1290
Air Flow [C]
•Gradually raise the vacuum (lower the pressure) applied to the vacuum switch valve, and check the valve operation. When the vacuum is low, the vacuum switch valve should permit air to flow. When the vacuum raises to valve closing pressure, it should stop air flow.
Spring [A] Diaphragm [B] Valve [C]
Low Vacuum [D] Secondary Air Flow [E]
If the vacuum switch valve does not operate as described, replace it with a new one.
NOTE
○To check air flow through the vacuum switch valve, just blow through the air cleaner hose.
Vacuum Switch Valve Closing Pressure (Open → Close) Standard: 41 49 kPa (310 370 mmHg, 6.0 7.1 psi)
High Vacuum [A]
Secondary air cannot flow [B]
Clean• Air System Hose Inspection
Be certain that all the hoses are routed without being flattened or kinked, and are connected correctly to the air cleaner housing, vacuum switch valve, #1 and #4 carburetor holders and air suction valve covers.
If they are not, correct them. Replace them if they are damaged.
5-12 ENGINE TOP END
Cylinder Head Cover
Cylinder• Head Cover Removal
Remove:
Fuel Tank (see Fuel System (DFI) chapter)
Vacuum Switch Valve and Hoses
Stick Coils (see Electrical System chapter)
Air Suction Valve Covers [A]
•Removecover. the cylinder head cover bolts [A] and take off the
Cylinder• Head Cover Installation
•Replace the head cover gasket with a new one.
Apply silicone sealant [A] to the cylinder head as shown.
Sealant - Kawasaki Bond (Silicone Sealant): 56019-120
•Install:Dowel Pins [A]
Plug Hole Gaskets [B]
•Install the washer [A] with the metal side faces upward.
ENGINE TOP END 5-13
Cylinder Head Cover
•Tighten the cover bolts following the specified tightening sequence.
Torque - Cylinder Head Cover Bolts [B]: 9.8 N·m (1.0 kgf·m,
• 87 in·lb)
Install the removed parts (see appropriate chapters).