Kawasaki 750/800 Billet Head Instructions
Quantity ADA Part# Description
1 KA750/800 Billet head Shell
2 KA75cc or KA80cc Removable Dome (last 2 #’s=dome size)
2 OR042 Compression Oring - Dome to Cylinder
2 OR024 Head Shell to Dome Oring
2 OR020 Oring Around Top of Dome
1 ORKA750 Outer Head Shell Water Sealing Oring
2 BF183890 90° Brass Fitting - 1/8” npt by 3/8” hose barb
1 BF18PLG Brass Plug - 1/8” npt
Installation Procedure
1) Remove the stock head and clean the top surface of the cylinder.
2) Install the domes and all orings in the ADA billet head. Use grease to hold orings in
place, do not use glue or gasket sealer of any kind!
3) Install the ADA billet head onto the cylinder with the water outlets on the carburetor
side. Make sure that all orings stay in place and do not come out of their groove,
causing them to get pinched.
4) Install the stock nuts and washers, first torque to 15ft/lbs then to 18ft/lbs. The
torque pattern should be done the same as the stock head, center of head outwards.
Re-torque the head bolts after the initial use and then periodically thereafter.
5) Water routing can be done different ways and careful experimentation is recom-
mended. However, it is best to start with the stock water routing or if using an af-
termarket exhaust system, the recommendations of the pipe manufacturer. When
experimenting with water routing, always check front and rear cylinder temperature
for consistency.
6) If you are using a girdle head, please follow the instructions that came with the ADA
girdle kit for girdle installation.
Read First!
Please read these instructions completely through before starting the installation. If
you are also installing a girdle kit, read those instructions beforehand as well.
Please note that the ADA billet head is installed with the water outlets on the carburetor
side of the engine. The ADA billet head does not use a head gasket and must be in-
stalled with the outlets on the carb side for proper cooling.
Do not use silicone or gasket sealer on any of the head surfaces.
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Kawasaki 750/800 Girdle Kit Instructions
Quantity ADA Part# Description
1 KA800BRK-F Front Billet Girdle Bracket
1 KA800BRK-R Rear Billet Girdle Bracket
4 HW10X71STUD 10 x 71mm Stud
4 HW10X130ALN 10-1.5 x 130mm Allen Bolt
4 HW10MMFLT 10mm Flat Washer - small OD
2 HW6X35HEX 6 x 35mm Hex Bolt
2 HW6X40HEX 6 x 40mm Hex Bolt
4 HW6MMFLT 6mm Flat Washer
Installation Procedure
1) Remove the head and cylinder.
2) Remove the front and rear 2 stock cylinder studs. Install the supplied studs, making
sure the stud is installed all of the way into the cases.
3) Remove the rear coupler cover and cable bracket. Remove the two 6mm studs that
hold the cover and bracket to the cases. Do not re-install the cable bracket, instead
secure any lines to the girdle bracket.
4) Re-install the cylinder, making sure to replace the base gasket if necessary.
5) Slide the front and rear girdle brackets onto the studs, lifting the cylinder slightly.
6) Install the stock 10mm acorn nuts onto the studs, again lifting the cylinder to install
the nuts on the exhaust side. Only hand tighten the nuts at this time.
7) Install the 6x40mm hex bolts with flat washer into the front bracket and the 6x35mm
bolts through the coupler cover into the rear bracket. Lightly tighten these bolts.
8) Snug the cylinder nuts, and then tighten the 6mm hex bolts. Make sure the brackets
are contacting both the case and the cylinder, leaving no gaps.
9) Torque the cylinder bolts to 22ft/lbs.
10) Install the ADA billet head according to instructions provided with the billet head.
11) Install the 10x130mm allen bolts, torque to 18ft/lbs.
12) Check installation and re-torque bolts after 1st time out and periodically there-after.
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