Gasket-head 11004-2104

Removed the head and cleaned throughly. Replaced with new head seal and other seals. I did not set the intake valves clearance. I got by this by carefully inserting the rods as I put the gasket in place and screwed the head in. As I tightened the head, the rods went in place tighter. I never changed the piston, rotation of the engine, or gap setting on the head. Worked perfectly.

Download Kawasaki FD440V service manual for torques.
Disconnect spark plug wires.
Drain coolant, remove cooler, fan, cooler support bolts and fan duct for access to manifold bolts.

Special note: cooler stand off bolts have "non-permanent" thread lock agent on engine housing thread. Cooler support bolt may brake off in engine housing , Drill broken bolt out of the engine housing. do not use an "easy-out" to remove bolt. the "easy-out" will break off in the hole. The broken "easy-out" can be removed by grinding. otherwise total job is less than 2 hours.

Disconnect exhaust and intake manifold from cylinder heads.
Disconnect sensor and hoses from left cylinder
Remove valve cover and cylinder heads
Clean the surfaces that contact the head and intake gaskets. do not scratch the surfaces.
Install head gasket and intake manifold gaskets.
Torque cylinder head bolts.
Re-install valve cover, cooling system parts and re-connect sensor
Add coolant and leak-check head gaskets by cranking engine and looking for air bubbles in coolant.
Install exhaust gaskets
Connect spark plug wires
Test run engine

1. Remove radiator, fan and plastic housing, noting where spacer washers are.
2. Remove cylinder head
3. Clean head surfaces completely, using fine grade sand paper and a good flat surface
4. Apply copper coat head gasket coating to head gasket
5. Replace head, be sure to torque head bolts properly and in proper sequence
6. Re-install radiator and fan, and housing
7. Perform cylinder compression test and radiator coolant pressure test

Disassembled parts to get to head gaskets and replaced with new gaskets....
Reassembled parts to torque specs and using feeler gauge.
Took my time and folowed written instructions, U-tube, and expert advice from friends in the know.
I saved a lot of money!
Thank you eReplacementParts.com!
No way I could have done it without access to your available and affordable parts !