Kawasaki 900 / 1100 Engine Removal and Installation

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Filed Under (Kawasaki) by admin on 01-05-2012

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1.1 (Above) Remove the two retaining straps, disconnect the battery and remove it from the hull. Disconnect the negative (black) cable first, then the positive (red). Step 2 Intake Removal 2.1 (Below) Remove the eight 10mm bolts securing the flame arrestor cover to the base and remove it. 2.2 (Below) Pull out the flame arrestor screens. 2.3 (Below) Remove the six 10mm bolts securing the flame arrestor base and carbs to the manifold and remove the base. 2.4 (Below) Loosen the gas tank cap to relieve pressure. Be sure the fuel switch is turned to the “OFF” position, and be aware of any fuel that may spill from the hoses. Make sure the hull is clear of any gasoline fumes before continuing work, especially with power tools. Remove the pulse lines from the block, and the three oil lines from the carbs. Move the carbs aside in the hull. 2.5 (Below) Remove the 18 10mm nuts from the studs securing the intake manifold to the engine and remove the manifold

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Kawasaki 900/1100 Billet Head Installation And REMOVAL Instructions

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Filed Under (Kawasaki) by admin on 25-10-2010

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1) Remove stock head and clean the top surface of the cylinder. 2) Remove the stock water fitting from the stock head and install it in the ADA Racing® billet head in the center cylinder location. Install the 1/8″ npt brass plugs in the 2 outer cylinder locations. 3) Install all o’rings in the ADA Racing® billet head, use small amounts of grease to hold them in place, do not use super glue or silicone. 4) Apply a small amount of grease to the small (OR020) o’ring at the top of the dome. This will allow the dome to easily slip into the head shell. Be careful when turning the head upside down to install onto the cylinder, as the domes can slide out of the head shell. 5) Make sure all the o’rings are in place and place the head on top of the cylinder with the water outlet on the intake side. You must be sure that none of the o’rings slip out of their groove, as this will cause an o’ring to get pinched and a water or compression leak could result. 7) Torque all of the nuts to 15ft/lbs, in a center-out criss-cross pattern. Now, torque them again to 18ft/lbs. 8) After the 1st time out riding the head should be re-torqued. 9) The 2 additional 1/8″ npt holes in the ADA Racing® billet head come with brass plugs, but barbed fittings can be installed for custom water routing applications.

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