KX500 HEAD TORQUE SPECS WITH TECH TIPS

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I've been asked many times about how to torque the head...
Below is a picture of the order I use.

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But before you get all excited and start twisting wrenches... Get the head and the cylinder mating surfaces flat and clean, clean, clean...
Inspect both surfaces for any defects or cracks...

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It's hard to see in the above pictures but the stud holes have all been chamfered.
Even though the cylinder was decked the area touching the stud has a tendency to pull slightly upward and can cause the gasket not to seal.
Just a slight bit of chamfer will prevent that from happening.

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What gasket to use.
I only recommend two different gaskets.
1. Cometic
2. OEM

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Torque specs:

ft/lb 18
Nm 25

WAIT

Don't start cranking them down.
Look at the torque order below..

HEAD.jpg (183.96 KiB) Viewed 5760 times

Set your torque wrench to 6 ft/lb or 8 Nm and follow the chart.
Now, set your torque wrench to 12 ft/lb or 16 Nm and follow the chart again.
Not done yet... set your torque wrench to 18 ft/lb or 25 Nm and again, follow the chart.
You only wish you were done... leaving the torque wrench set at 18 ft/lb or 25 Nm check them all one more time.

Now you are ready to start your heat cycles.
Before you take your bike on it's maiden voyage, get your torque wrench out again set it at 18 ft/lb or 25 Nm check them all again.
Once you have a full tank of gas through it, check them one last time.
You should be good to go.

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How do I feel about the use of products like Copper Tack or case sealant.
I have used copper tack but never case sealant.
Copper tack works as advertised but it will not fix a bad gasket or poor sealing surfaces.
I have used it extensively with copper head gaskets.
I do not like copper gaskets but you can make them work.

Doug Haas (Former Kawasaki Factory Engineer)
John Braash (Former Kawasaki Factory Race Tech)
Both use a sealant on their heads
I was very surprised.
I'll see if I can get additional info as to which brand they use.

Lapping.
Lapping is great and Timesaver 100 is the best lapping compound that I have ever found.
This picture shows Medium 60 but Fine 100 is what I use.

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Comments from Doug Haas:

i use a very thin layer of silicone on the head side of the gasket.
The gasket comes off with the head.
The head is easier to clean up then the cylinder.