• Remove:
Thermostat Housing Mounting Bolts [C]
Thermostat Assembly [D]

• Remove:
Thermostat Cap Bolts [A]
Thermostat Cap [B] and Housing [C]
Thermostat [D]
O-rings [E]

COOLING SYSTEM 4-19
Thermostat
Thermostat Installation

the O-rings with new ones.
• Replace
liquid gasket to any positions of the O-ring [A] to
• Apply
prevent it from coming off.
Sealant - Liquid Gasket, TB1211F: 92104-0004

○Do not apply grease to the O-ring [B].

• Assemble:
O-rings

Thermostat Housing [C]
Thermostat [D]
Thermostat Cap [E]

○Install the thermostat [A] in the housing so that the air

•

bleeder hole [B] is on top.
Tighten:
Torque - Thermostat Cap Bolts: 6.0 N·m (0.61 kgf·m, 53
in·lb)

the thermostat housing to the cylinder head.
• Install
Tighten:
•
Torque - Thermostat Housing Mounting Bolts: 10 N·m (1.0
kgf·m, 89 in·lb)

• Install the removed parts (see appropriate chapters).
Thermostat Inspection

the thermostat (see Thermostat Removal).
• Remove
the thermostat valve [A] at room temperature.
• Inspect
If the valve is open, replace the thermostat with a new
one.

check valve opening temperature, suspend the ther• To
mostat [A] in a container of water and raise the temperature of the water.

○The thermostat must be completely submerged and must
not touch the container sides or bottom. Suspend an accurate thermometer [B] in the water so that the heat sensitive portions [C] are located in almost the same depth.
It must not touch the container, either.
If the measurement is out of the specified range, replace
the thermostat with a new one.
Thermostat Valve Opening Temperature
58  62°C (136  144°F)

4-20 COOLING SYSTEM
Hoses and Pipes
Hose Installation

the hoses and pipes, being careful to follow bend• Install
ing direction. Avoid sharp bending, kinking, flattening or
twisting.
Run the hoses (see Cable, Wire, and Hose Routing section in the Appendix chapter).
Install the clamp [A] as near as possible to the hose end
to clear the raised rib of the fitting. This will prevent the
hoses from working loose.
○The clamp screws should be positioned correctly to prevent the clamps from contacting the other parts.
○Tighten:

•
•

Torque - Water Hose Clamp Screws: 3.0 N·m (0.31 kgf·m,
27 in·lb)

Hose Inspection

to the Water Hose and Pipe Inspection in the Peri• Refer
odic Maintenance chapter.

COOLING SYSTEM 4-21
Water Temperature Sensor
Water Temperature Sensor Removal/Installation

to the Water Temperature Sensor Removal/Instal• Refer
lation in the Self-Diagnosis System chapter.

Water Temperature Sensor Inspection

to the Water Temperature Sensor Inspection in the
• Refer
Electrical System chapter.

ENGINE TOP END 5-1

Engine Top End
Table of Contents
Exploded View...................................
Exhaust System Identification ...........
Specifications ....................................
Special Tools and Sealant .................
Clean Air System...............................
Air Suction Valve Removal...........
Air Suction Valve Installation........
Air Suction Valve Inspection ........
Air Switching Valve Removal .......
Air Switching Valve Installation ....
Air Switching Valve Operation
Test............................................
Air Switching Valve Unit Test .......
Clean Air System Hose
Inspection..................................
Cylinder Head Cover .........................
Cylinder Head Cover Removal ....
Cylinder Head Cover Installation .
Camshaft Chain Tensioner ................
Camshaft Chain Tensioner
Removal ....................................
Camshaft Chain Tensioner
Installation .................................
Camshaft, Camshaft Chain ...............
Camshaft Removal ......................
Camshaft Installation ...................
Camshaft, Camshaft Cap Wear
Inspection..................................
Camshaft Runout Inspection........
Cam Wear Inspection ..................
Camshaft Chain Removal ............
Camshaft Chain Installation .........
Cylinder Head....................................
Cylinder Compression
Measurement ............................
Cylinder Head Removal ...............

5-2
5-6
5-8
5-9
5-11
5-11
5-11
5-12
5-12
5-12
5-13
5-13
5-13
5-14
5-14
5-14
5-16
5-16
5-17
5-19
5-19
5-20
5-22
5-23
5-23
5-23
5-24
5-25
5-25
5-26

Cylinder Head Installation ............
Cylinder Head Warp Inspection ...
Valves ................................................
Valve Clearance Inspection .........
Valve Clearance Adjustment........
Valve Removal .............................
Valve Installation ..........................
Valve Guide Removal ..................
Valve Guide Installation ...............
Valve-to-Guide Clearance
Measurement (Wobble
Method) .....................................
Valve Seat Inspection ..................
Valve Seat Repair ........................
Throttle Body Assy Holder.................
Throttle Body Assy Holder
Removal ....................................
Throttle Body Assy Holder
Installation .................................
Muffler................................................
Muffler Body Removal..................
Muffler Body Installation...............
Premuffler Chamber Removal .....
Premuffler Chamber Installation ..
Exhaust Pipe Removal.................
Exhaust Pipe Installation..............
Exhaust Butterfly Valve Cable
Removal ....................................
Exhaust Butterfly Valve Cable
Installation .................................
Exhaust Butterfly Valve Actuator
Removal ....................................
Exhaust Butterfly Valve Actuator
Installation .................................
Exhaust Butterfly Valve Actuator
Adjustment ................................

5-27
5-28
5-29
5-29
5-29
5-29
5-29
5-29
5-30

5-30
5-31
5-31
5-36
5-36
5-36
5-37
5-37
5-38
5-39
5-40
5-40
5-42
5-43
5-44
5-45
5-46
5-47

5

5-2 ENGINE TOP END
Exploded View

ENGINE TOP END 5-3
Exploded View
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17

Fastener
Air Suction Valve Cover Bolts
Sub Cover Bolts
Cylinder Head Cover Bolts
Camshaft Sprocket Bolts
Upper Camshaft Chain Guide Bolts
Camshaft Cap Bolts
Throttle Body Assy Holder Bolts
Cylinder Head Bolts (M6)
Water Passage Plugs
Cylinder Head Bolts (M10), Final
Cylinder Head Bolts (M10), First
Front Camshaft Chain Guide Bolt (Upper)
Front Camshaft Chain Guide Bolt (Lower)
Camshaft Chain Tensioner Mounting Bolts
Camshaft Chain Tensioner Cap Bolt
Coolant Drain Bolt (Cylinder)
Camshaft Chain Tensioner Cap Bolt
Cylinder Head Plug

N·m
10
10
10
15
12
12
10
12
20
58
30
25
12
10
5.0
10
20
25

Torque
kgf·m
1.0
1.0
1.0
1.5
1.2
1.2
1.0
1.2
2.0
5.9
3.1
2.5
1.2
1.0
0.51
1.0
2.0
2.5

ft·lb
89 in·lb
89 in·lb
89 in·lb
11
106 in·lb
106 in·lb
89 in·lb
106 in·lb
15
43
22
18
106 in·lb
89 in·lb
44 in·lb
89 in·lb
15
18

Remarks

18. ZX1000RH/SH/ZH
19. ZX1000Z
EO: Apply engine oil.
G: Apply grease.
L: Apply a non-permanent locking agent.
LG: Apply liquid gasket.
M: Apply molybdenum disulfide grease.
MO: Apply molybdenum disulfide oil solution.
(mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10:1)
R: Replacement Parts
S: Follow the specified tightening sequence.

L
L
S
L
S
S
L, S
S
L
MO, S
MO, S

5-4 ENGINE TOP END
Exploded View

ENGINE TOP END 5-5
Exploded View
No.
1
2
3
4
5
6
7
8

Fastener
Exhaust Butterfly Valve Actuator Pulley Bolt
Exhaust Butterfly Valve Actuator Mounting
Screws
Exhaust Pipe Holder Nuts
Clamp Mounting Bolt
Exhaust Pipe Clamp Bolt
Premuffler Chamber Mounting Bolt
Muffler Body Clamp Bolt
Muffler Body Mounting Bolt

9. ZX1000Z
R: Replacement Parts
S: Follow the specified tightening sequence.

N·m
5.0

Torque
kgf·m
0.51

ft·lb
44 in·lb

1.2

0.12

11 in·lb

20
8.0
17
34
17
25

2.0
0.82
1.7
3.5
1.7
2.5

15
71 in·lb
13
25
13
18

Remarks

S

5-6 ENGINE TOP END
Exhaust System Identification

Exhaust Pipe Mark Position [A]

Premuffler Chamber Mark Position [A]

ENGINE TOP END 5-7
Exhaust System Identification
Muffler Body Mark Position [A]

Exhaust Pipe [A] with Hole [B] for Oxygen Sensor [C]

Honeycomb Type Catalyst Positions [A]

5-8 ENGINE TOP END
Specifications
Item

Standard

Service Limit

Camshafts
Cam Height:
Exhaust
Intake
Camshaft Journal/Camshaft
Cap Clearance
Camshaft Journal Diameter

35.043  35.157 mm (1.3796  1.3841 in.)
38.243  38.357 mm (1.5056  1.5101 in.)
0.038  0.081 mm (0.0015  0.0032 in.)

34.94 mm (1.376 in.)
38.14 mm (1.502 in.)
0.17 mm (0.0067 in.)

23.940  23.962 mm (0.94252  0.94338
in.)
24.000  24.021 mm (0.94488  0.94571
in.)
TIR 0.02 mm (0.0008 in.) or less

23.91 mm (0.9413 in.)

Camshaft Bearing Inside
Diameter
Camshaft Runout
Cylinder Head
Cylinder Compression

Cylinder Head Warp
Valves
Valve Clearance:
Exhaust
Intake
Valve Head Thickness:
Exhaust
Intake
Valve Stem Bend
Valve Stem Diameter:
Exhaust
Intake
Valve Guide Inside Diameter:
Exhaust
Intake
Valve/Valve Guide
Clearance (Wobble Method):
Exhaust
Intake
Valve Seat Cutting Angle
Valve Seating Surface:
Width:
Exhaust
Intake
Outside Diameter:
Exhaust
Intake
Valve Spring Free Length:
Exhaust
Intake

(Usable Range)
875  1 348 kPa (8.93  13.75 kgf/cm²,
127  195.5 psi) @320 r/min (rpm)
–––

0.17  0.22 mm (0.0067  0.0087 in.)
0.15  0.22 mm (0.0059  0.0087 in.)
0.8 mm (0.031 in.)
1.25 mm (0.049 in.)
TIR 0.01 mm (0.0004 in.) or less

24.08 mm (0.9480 in.)
TIR 0.1 mm (0.004 in.)

– – –
0.05 mm (0.0020 in.)

– – –
– – –
0.4 mm (0.016 in.)
0.6 mm (0.024 in.)
TIR 0.05 mm (0.002 in.)

4.470  4.485 mm (0.1760  0.1766 in.)
4.475  4.490 mm (0.1762  0.1768 in.)

4.46 mm (0.176 in.)
4.46 mm (0.176 in.)

4.500  4.512 mm (0.1772  0.1776 in.)
4.500  4.512 mm (0.1772  0.1776 in.)

4.58 mm (0.180 in.)
4.58 mm (0.180 in.)

0.04  0.12 mm (0.0016  0.0047 in.)
0.03  0.10 mm (0.0012  0.0039 in.)
32°, 45°, 60°

0.31 mm (0.012 in.)
0.30 mm (0.012 in.)
– – –

0.8  1.2 mm (0.031  0.047 in.)
0.5  1.0 mm (0.020  0.039 in.)

– – –
– – –

24.9  25.1 mm (0.980  0.988 in.)
30.4  30.6 mm (1.197  1.205 in.)

– – –
– – –

40.4 mm (1.59 in.)
43.8 mm (1.72 in.)

38.9 mm (1.53 in.)
42.0 mm (1.65 in.)

ENGINE TOP END 5-9
Special Tools and Sealant
Compression Gauge, 20 kgf/cm²:
57001-221

Valve Seat Cutter, 32° 57001-1119