Kawasaki KLE500 (2004) [134/401] 22 engine top end

5-22 ENGINE TOP END

Cylinder Head

If cylinder compression is lower than the usable range,

check the following:

1. Gas leakage around the cylinder head - replace the

damaged gasket and check the cylinder head for

warping.

2. Condition of the valve seating.

3. Valve clearance - if a valve requires an unusually

large adjustment to obtain proper clearance, the valve

may be bent, and not seating completely.

4. Piston/cylinder clearance, piston seizure.

5. Piston ring, piston ring groove.

Cylinder Head Removal

•

Remove:

Cylinder Head Cover (see Cylinder Head Cover Re-

moval)

Exhaust Pipes and Mufflers (see Crankshaft/Transmis-

sion chapter)

Cam Chain Tensioner (see Chain Tensioner Removal)

Camshafts (see Camshaft Removal)

Carburetors (see Carburetor Removal in the Fuel Sys-

tem chapter)

•

Remove the main oil pipe banjo bolts [A].

•

Loosen the main oil pipe mounting bolt [B].

•

Remove the rear 6 mm cylinder head bolt [C].

•

Remove the front 6 mm c ylinder head bolt [A] first, then

remove the 10 mm cylinder head bolts [B] This prevents

excessive stress on the small bolts.