Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004

• Install:

Dowel Pins [C]

Plug Hole Gaskets [D]

 

• Install:

Washers [A]

Cylinder Head Cover Bolts [B]

○Install the washers with metal side [C] faces upward.

• Tighten:

Torque - Cylinder Head Cover Bolts: 9.8 N·m (1.0 kgf·m, 87

in·lb)

 

Cylinder Head Cover

• Install the baffle plate [A].

• Tighten:

Torque - Baffle Plate Bolts [B]: 5.9 N·m (0.60 kgf·m, 52 in·lb)

 

Camshaft Chain Tensioner

Camshaft Chain Tensioner Removal

CAUTION

This is a non-return type camshaft chain tensioner. The push rod does not return to its original position once it moves out to take up camshaft chain slack. Observe all the rules listed below: When removing the tensioner, do not take out the mounting bolts only halfway. Retightening the mounting bolts from this position could damage the tensioner and the camshaft chain. Once the bolts are loosened, the tensioner must be removed and reset as described in “Camshaft Chain Ten- sioner Installation.” Do not turn over the crankshaft while the tensioner is removed. This could upset the camshaft chain timing, and damage the valves.

• Remove:

Right Center Fairing (see Center Fairing Removal in the

Frame chapter) Cap Bolt [A] Washer [B] Spring [C]

• Remove the mounting bolts [D] and take off the camshaft

chain tensioner.

 

 

Camshaft Chain Tensioner Installation

• Release the stopper [A] and push the push rod [B] into the tensioner [C].

• Install the tensioner so that the stopper faces upward.

 

 

• Tighten the tensioner mounting bolts [A].

Torque - Camshaft Chain Tensioner Mounting Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)

• Install the spring and washer.

• Tighten the cap bolt [B].

Torque - Camshaft Chain Tensioner Cap Bolt: 20 N·m (2.0 kgf·m, 15 ft·lb)

• Turn the crankshaft 2 turns clockwise to allow the ten-

sioner to expand and recheck the camshaft chain timing.

 

Camshaft Removal

• Remove:

Cylinder Head Cover (see Cylinder Head Cover Re-

moval)

Right Lower Fairing (see Lower Fairing Removal in the Frame chapter)

• Position the crankshaft as follows.

○Remove the upper [A] and lower [B] caps on the clutch

cover.

 

○Using a wrench on the crankshaft rotation bolt, turn the crankshaft clockwise until the 2/T mark line [A] on the tim- ing rotor is aligned with the notch [B] in the edge of the upper hole [C] in the clutch cover.

 

 

• Remove:

Camshaft Chain Tensioner (see Camshaft Chain Ten-

CAUTION

The crankshaft may be turned while the camshafts are removed. Always pull the chain taut while turn- ing the crankshaft. This avoids kinking the chain on the lower (crankshaft) sprocket. A kinked chain could damage both the chain and the sprocket.

sioner Removal) Camshaft Cap Bolts [A] Camshaft Caps [B] Camshafts [C]

Camshaft Installation

• Be sure to install the following parts. Plug Hole Gaskets [A]

Dowel Pins [B]

 

• Apply molybdenum disulfide oil solution to all cams [A] journals [B] and thrust blocks [C] with × marks.

• If a new camshaft is to be used, apply a thin coat of molyb-

denum disulfide grease to the cam surfaces.

NOTE

○The exhaust camshaft has a 2 412 EX mark [D] and the

inlet camshaft has a 2 412 IN mark [E]. Be careful not

to mix up these shafts.

• Position the crankshaft as follows.

• Pull the tension side (exhaust side) of the chain taut to

install the chain.

• Engage the camshaft chain with the camshaft sprockets so that the timing marks on the sprockets are positioned

as shown.

○Using a wrench on the crankshaft rotation bolt, turn the

crankshaft clockwise until the 2/T mark line [A] on the tim-

ing rotor is aligned with the notch [B] in the edge of the upper hole [C] in the clutch cover.

• If the clutch cover is removed, perform the next proce- dure.

○Using a wrench on the crankshaft rotation bolt, turn the

crankshaft clockwise until the 1/T mark line [A] on the

timing rotor is aligned with the wating surface [B] of the crankcase halves.

 

 

○The timing marks must be aligned with the cylinder head upper surface [C].

EX Mark [D] (Between #1 Pin and #2 Pin) IN Mark [E] (Between #31 Pin and #32 Pin)

#1 Pin [F]

#2 Pin [G]

#31 Pin [H]

#32 Pin [J]

 

• Install the camshaft cap, while pushing the camshaft chain, tighten all camshaft bolts and chain guide bolts.

NOTE

○The exhaust cap has a “EX” mark [A] and the inlet cap

has a “IN” mark [B]. Be careful not to mix up these caps.

○First tighten all the camshaft cap bolts evenly to seat the camshaft in place, then tighten all bolts following the spec- ified tightening sequence.

Torque - Camshaft Cap Bolts (1 ~ 12): 12 N·m (1.2 kgf·m,

106 in·lb)

• Install:

Camshaft Chain Tensioner (see Camshaft Chain Ten-

sioner Installation)

Cylinder Head Cover (see Cylinder Head Cover Instal- lation)

Right Lower Fairing (see Lower Fairing Removal in the Frame chapter)

 

 

Camshaft and Sprocket Assembly

○The inlet and exhaust sprockets are identical.

CAUTION

Inlet sprocket must use “IN” marked bolts holes [A]. Exhaust sprocket must use “EX” marked bolts holes [B].

• Install the sprockets so that the marked (“IN” and “EX”) side faces to the right side.

• Apply a non-permanent locking agent to the camshaft sprockets bolts and tighten them.

Torque - Camshaft Sprockets Bolts: 15 N·m (1.5 kgf·m, 11 ft·lb)

If a new camshaft is to be used, apply a thin coat of a molybdenum disulfide grease to the cam surfaces.

Camshaft, Camshaft Cap Wear

• Remove:

Camshaft Caps (see Camshaft Removal)

• Cut strips of plastigage to journal width. Place a strip on each journal parallel to the camshaft installed in the

correct position.

• Measure each clearance between the camshaft journal and the camshaft cap using plastigage (press gauge) [A].

• Tighten:

Torque - Camshaft Cap Bolts: 12 N·m (1.2 kgf·m, 106 in·lb)

NOTE

○Do not turn the camshaft when the plastigage is be-

tween the journal and camshaft cap.