Kawasaki Z400 - Service manual > Cylinder Head Cover

Cylinder Head Cover Removal

• Replace the M cover gasket with a new one.
• Clean off any oil or dirt and apply liquid gasket to the groove [A] of the cylinder head cover.

Sealant - Liquid Gasket , TB1211F: 921044004

NOTE

Make the tightening the cylinder head cover bolts finish within 60 minutes when the liquid gasket  is applied.

• Install the gasket to the cylinder head cover.
• Apply liquid gasket [A] to the head cover gasket as shown.

Sealant - Liquid Gasket, TB12168: 921 04-1 064

NOTE

Make the tightening the cylinder head cover bolts finish within 30 minutes when the liquid gasket is applied.

• Replace the washers [A] with new ones.
• Install the washers with metal side faces upward.
• Tighten: Torque -Cylinder Head Cover Bolts: 9.8 Nm (1.0 kgf*m, 87 in*lb)
• Install the removed parts (see appropriate chapters).

Camshaft Chain Tensioner

Camshaft Chain Tensioner Removal

NOTICE

This Is a non-return type camshaft chain tensioner.

The push rod does not return to Its original position once It moves out to take up camshaft chain slack.

Observe all the rules listed below.

When removing the tensioner, do not take out the mounting bolts only halfway. Retightening the mounting bolts from this position could damage the tensioner and the camshaft chain. Once the bolts are loosened, the tensioner must be removed and reset as described in "Camshaft Chain Tensioner Installation." Do not turn over the crankshaft while the tensioner is removed. This could upset the camshaft chain timing, and damage the valves.

• Remove: Right Middle Fairing (see Middle Fairing Removal in the Frame chapter) Frame Bracket Bolts [A] Right Frame Bracket [B]

• Remove: cap Bolt [A] Washer [B]

• Remove: Spring [A] Camshaft Chain Tensioner Mounting Bolts [B] Camshaft Chain Tensioner [C]

Camshaft Chain Tensioner Installation

• Replace the O-ring [A] with a new one.
• Apply grease to the new O-ring.
• Adjust the position of push rod [B].

Insert  it fully.

Pull wt it as shown.

6 Notches [C] (5 clicks)

• Install the tensioner body [A] so that the stopper races upward.
• Tighten the tensioner mounting bolts [B].

Toque - Camshaft Chain Tensioner Mounting Bolts: 9.8 N-m (1.0 kgf*m, 87 in-lb)

• Install: spring [A] Washer [B]
• Tighten: Torque - Camshaft Chain Tensioner Cap Bolt [C] :20N*m (2.0 kgf*m, 15 ft-lb)

• Install: Right Frame Bracket
• Tighten: Toque - Frame Bracket Bolts: 34 N-m (3.5 kgf*m, 25 R-lb)

Tighten the front side bolt first.

• Install the right middle fairing (see Middle Fairing Installation in the Frame chapter).

See also: