Special Tools and Sealant

Compression Gauge Adapter, M10 × 1.0: 57001-1317

Piston Pin Puller: 57001-1568

Valve Seat Cutter Holder, 4.5: 57001-1330

Piston Pin Puller Adapter C: 57001-1657

Valve Guide Arbor, 4.5: 57001-1331

Kawasaki Bond (Silicone Sealant): 92104-0004

Valve Guide Reamer, 4.5: 57001-1333

Clean Air System

Air Suction Valve Removal

_• Remove:

Fuel Tank (see Fuel Tank Removal in the Fuel System

(DFI) chapter)

Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter)

Air Switching Valve with Hoses (see Air Switching Valve Removal)

Air Suction Valve Cover Bolts [A] and Clamp Air Suction Valve Cover [B]

Air Suction Valve [C]

Air Suction Valve Installation

_• Install the air suction valve [A] so that its side where stop- per is fixed with the screws [B] faces the front [C] .

_• Tighten:

Torque - Air Suction Valve Cover Bolts: 9.8 N·m (1.0 kgf·m,

87 in·lb)

Air Suction Valve Inspection

_• Remove the air suction valve (see Air Suction Valve Re- moval).

_• Visually inspect the reeds for cracks, folds, warps, heat

damage or other damage.

If there is any doubt as to the condition of the reeds [A], replace the air suction valve as an assembly.

_• Check the reed contact areas [B] of the valve holder for

grooves, scratches, any signs of separation from the

holder or heat damage.

_• If there is any doubt as to the condition of the reed contact areas, replace the air suction valve as an assembly.

_• If any carbon or other foreign particles have accumulated

between the reed and the reed contact area, wash the

valve assembly clean with a high-flash point solvent.

Air Switching Valve Removal

_• Remove:

Fuel Tank (see Fuel Tank Removal in the Fuel System

(DFI) chapter)

Air Switching Valve Connector [A] (Disconnect) Air Switching Valve [B]

Air Switching Valve Installation

_• Route the hoses correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter).

Clean Air System

Air Switching Valve Operation Test

_• Refer to the Air Switching Valve Operation Test in the Electrical System chapter.

Air Switching Valve Unit Test

_• Refer to the Air Switching Valve Unit Test in the Electrical System chapter.

Clean Air System Hose Inspection

_• Be certain that all the hoses are routed without being flat- tened or kinked, and are connected correctly to the air

cleaner housing, air switching valve, #1 and #2 throttle body holders and air suction valve covers.

If they are not, correct them. Replace them if they are damaged.

Cylinder Head Cover

Cylinder Head Cover Removal

_• Remove:

Fuel Tank (see Fuel Tank Removal in the Fuel System

(DFI) chapter)

Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter)

Air Suction Valve Cover [A] with Hose [B] Stick Coils [C]

Baffle Plate [D] Throttle Cables [E]

Clutch Cable Holder [F] with Bolt [G] Cylinder Head Cover Bolts [H] Cylinder Head Cover [I]

EX650B Models

_• Remove the radiator with radiator hoses and move it forward (see Radiator and Radiator Fan Removal in the

Cooling System chapter).

Cylinder Head Cover Installation

_• Replace the head cover gasket [A] with a new one.

_• Apply silicone sealant [B] to the cylinder head as shown.

Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004

_• Install:

Dowel Pins [C]

Plug Hole Gaskets [D]

_• Install:

Washers [A]

Cylinder Head Cover Bolts [B]

○^{Install the washers with metal side [C] faces upward.}

_• Tighten:

Torque - Cylinder Head Cover Bolts: 9.8 N·m (1.0 kgf·m, 87

in·lb)