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Old April 24th, 2019, 05:00 PM   #1
FaceMower
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Replace Cylinder Head Cover?

TL;DR: Bought a 2013 Ninja 300 and found a puncture in the cylinder head cover. Looking for advice/instructions (Tools/Parts/Processes) on replacement of the cylinder head cover or any other options.

I am a new rider and I picked up a 2013 Ninja 300 with 4,900 for what I thought was a great deal. I took it out a couple times before I did an oil change with no problems. After I changed the oil I took it out a few more times and noticed a lot of oil covering the lower fairing on the right side. My first thought was that I under-tightened or over-tightened the oil filter but it was coming from higher up on the engine. After removing the fairings I noticed it was coming from the cylinder head cover. The previous owner had no-cut frame sliders installed and the brackets line up with the cylinder head covers. I was told it was dropped once and the only damage I noticed when purchasing it was a missing passenger peg and a few scratches. Turns out the frame slider bracket collided with and punctured the cylinder head cover. This puncture was the source of the oil leak.

I am considering replacing the cylinder head cover myself but have basically zero experience with motorcycle engines. I have some experience with basic car mechanics such as changing brake systems, suspensions, and cold air intakes. I have minimal experience assisting friends and relatives in engine and transmission work. Does anyone have experience in this process that could tell me how difficult of a task it is?

I have Kawasaki service manual for the bike but I feel like I might be missing some steps since I have never done work like this before. Does the service manual include everything I need to know? Do I need to drain the oil and siphon the gas before I remove the cylinder head? Do I need to remove the gas tank?

Cylinder Head Cover: Pages 236 - 237
Service Manual: https://www.manualslib.com/manual/80...age=236#manual

I would also like to know what I will all need to replace besides the cylinder head cover. I know I will need a new cylinder head cover gasket but will I need all new bolts and washers/O-rings? Will I need new plug hole gaskets/pins and a new "VALVE-ASSY-REED" under the "CAP"? I put a link below so you can see what I am talking about.
Exploded View: https://www.kawasakipartshouse.com/o...der-head-cover

My last question was about tools. I believe I have everything I need to complete this replacement but I wanted to know if there was any special tools required? Will I need a compression gauge to check the engine after I install the new cylinder head cover?

I am open to any other suggestions on fixes even if they are temporary. I'll take any videos or links that may help me out. I also uploaded some pictures of the bike. Apologizes for the lengthy post, I wanted to make sure I had everything covered.

Any help is much appreciated, thanks!
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Old April 25th, 2019, 06:21 AM   #2
jkv45
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I also posted this on another forum -


I'd probably replace it with a good used one.

No need for a new one, they typically aren't going to wear out or get damaged. Cross-check part numbers, but the 300 valve cover may be the exact same as the "New Gen" 250 valve cover - so they would be a dine-a-dozen and easy to get used. Even if not, there should be plenty of used 300 covers out there.

You gasket should be fine, as it's rubber and reusable.

This video showing valve cover removal is for the 250, but should be the same or very similar -

Link to original page on YouTube.

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Old April 25th, 2019, 07:04 AM   #3
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If you were to research valve clearance inspection in your manual, cover removal will be detailed as its removal is (obviously) required to gain access to accomplish said inspection.

While so convenient, you may want to check those valve clearances anyway.
The factory suggested mileage interval will be listed in the Maintenance Schedule.
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Old April 25th, 2019, 07:14 AM   #4
jkv45
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Plugs are right there, so it would be a good time to replace them as well.
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Old April 25th, 2019, 10:44 AM   #5
DannoXYZ
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Saw a racer fail tech-inspection for this issue.
Guy was on side trying to figure out what to do.
Another tech-inspector came over, took a look at it, and told him, "Duct-tape it!"

That was also their solution couple months earlier when rental U-haul trailer gouged hole in my belly-pan.

Of course, since this is a non-structural part, it can be repaired easily with some light tapping from inside, and TIG torch... or fibreglass... or some pigeons...

Get rid of those sliders too...

Last futzed with by DannoXYZ; April 26th, 2019 at 12:29 PM.
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Old December 24th, 2019, 03:36 PM   #6
Mohawk
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Bit late I know, but just rough that area with some sandpaper and then degrease it. Use some liquid metal filler to seal the hole. I have a crack like that in my 250 left case cover. Did the above to it 5 years ago, still going strong, no leaks and dry little couple cost to repair.
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Old December 24th, 2019, 06:35 PM   #7
SibSerge
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theoretically tapping from the inside to straighten it out and gluing on the oudside with a piece of aluminum patch and jbweld should do. The crankcase is under a negative pressure while running so even a ducktape will seal it
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