5-18 ENGINE TOP END. Cylinder Head Cover

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Valentine Bell
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1 5-18 ENGINE TOP END Cylinder Head Cover Cylinder Head Cover Installation Replace the head cover gasket [A] with a new one. Apply silicone sealant [B] to the cylinder head as shown. Sealant - Kawasaki Bond (Silicone Sealant): Replace the plug hole gaskets [A] with new ones. Be sure to install the following parts. Dowel Pins [B] Plug Hole Gaskets Install the rubber washers [A] with metal side faces upward. Tighten: Torque - Cylinder Head Cover Bolts: 9.8 N m (1.0 kgf m, 87 in lb)

2 Cylinder Head Cover Be sure that the dampers [A] of the baffle plate is in position. Tighten: Torque - Baffle Plate Bolts: 5.9 N m (0.60 kgf m, 52 in lb) ENGINE TOP END 5-19

5-20 ENGINE TOP END Camshaft Chain Tensioner Camshaft Chain Tensioner Removal CAUTION This is a non-return type camshaft chain tensioner.

Observe all the rules listed below: When removing the tensioner, do not take out the mounting bolts only halfway.

Once the bolts are loosened, the tensioner must be removed and reset as described in "Camshaft Chain Tensioner Installation.

3 5-20 ENGINE TOP END 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 Tensioner Installation." Do not turn over the crankshaft while the tensioner is removed. This could upset the camshaft chain timing, and damage the valves. Remove: Cap Bolt [A] Washer [B] Remove the spring [A]. Remove the mounting bolts [A] and take off the camshaft chain tensioner body.

Camshaft Chain Tensioner ENGINE TOP END 5-21 Camshaft Chain Tensioner Installation Replace the O-ring [A]

Release the stopper [B] and push the push rod [C] into the tensioner body [D].

Torque - Camshaft Chain Tensioner Mounting Bolts: 9.8 N m (1.

4 Camshaft Chain Tensioner ENGINE TOP END 5-21 Camshaft Chain Tensioner Installation Replace the O-ring [A] with a new one. Apply grease to the new O-ring. Release the stopper [B] and push the push rod [C] into the tensioner body [D]. Install the tensioner body so that the stopper [A] faces upward. Tighten the tensioner mounting bolts. Torque - Camshaft Chain Tensioner Mounting Bolts: 9.8 N m (1.0 kgf m, 87 in lb) Install: Spring [A] Washer [B] Tighten the cap bolt [C]. 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 tensioner to expand and recheck the camshaft chain timing.

5-22 ENGINE TOP END Camshaft, Camshaft Chain Camshaft Removal Remove: Cylinder Head Cover (see Cylinder Head Cover Removal) Timing Inspection Cap [A] Timing Rotor Bolt Cap [B] Using a wrench on the

5 5-22 ENGINE TOP END Camshaft, Camshaft Chain Camshaft Removal Remove: Cylinder Head Cover (see Cylinder Head Cover Removal) Timing Inspection Cap [A] Timing Rotor Bolt Cap [B] Using a wrench on the timing rotor bolt, turn the crankshaft clockwise until the 2/T mark line [A] on the timing rotor is aligned with the notch [B] in the edge of the timing inspection hole [C] in the clutch cover. If the clutch cover is removed, perform the next procedure. Using a wrench on the timing rotor bolt, turn the crankshaft clockwise until the 1/T mark line [A] on the timing rotor is aligned with the mating surface [B] of the crankcase front side.

6 Camshaft, Camshaft Chain Remove the camshaft chain tensioner (see Camshaft Chain Tensioner Removal). Loosen the camshaft cap bolts as shown sequence [1 12 ] in the figure, and remove them. Remove: Camshaft Caps [A] Camshafts [B] ENGINE TOP END 5-23 CAUTION The crankshaft may be turned while the camshafts are removed. Always pull the chain taut while turning the crankshaft. This avoids kinking the chain on the lower (crankshaft) sprocket. A kinked chain could damage both the chain and the sprocket. Stuff a clean cloth into the chain tunnel to keep any parts from dropping into the crankcase. Remove the cam sprocket mounting bolts [A]. Remove the cam sprocket.

7 5-24 ENGINE TOP END Camshaft, Camshaft Chain Camshaft Installation Replace the plug hole gaskets [A] with new ones. Be sure to install the following parts. Plug Hole Gaskets Dowel Pins [B] Install the cam sprockets so that the marked ( IN" and EX ) side faces to the outward. The inlet [A] and exhaust cam sprockets [B] are identical. CAUTION Inlet cam sprocket must use IN marked bolt holes [C]. Exhaust cam sprocket must use EX marked bolt holes [D]. Apply a non-permanent locking agent to the camshaft sprocket bolts and tighten them. Torque - Camshaft Sprocket Bolts: 15 N m (1.5 kgf m, 11 ft lb) 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 molybdenum disulfide grease to the cam surfaces. NOTE The exhaust camshaft has a 2412 EX mark [D] and the inlet camshaft has a 2412 IN mark [E]. Be careful not to mix up these shafts.

8 Camshaft, Camshaft Chain Using a wrench on the timing rotor bolt, turn the crankshaft clockwise until the 2/T mark line [A] on the timing rotor is aligned with the notch [B] in the edge of the timing inspection hole [C] in the clutch cover. CAUTION The crankshaft may be turned while the camshafts are removed. Always pull the chain taut while turning the crankshaft. This avoids kinking the chain on the lower (crankshaft) sprocket. A kinked chain could damage both the chain and the sprocket. ENGINE TOP END 5-25 If the clutch cover is removed, perform the next procedure. Using a wrench on the bolt, turn the crankshaft clockwise until the 1/T mark line [A] on the timing rotor is aligned with the mating surface [B] of the crankcase front side. Pull the tension side (exhaust side) [A] 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 sown. The timing marks must be aligned with the cylinder head upper surface [B]. EX Mark [C] (Between #1 Pin and #2 Pin) IN Mark [D] (Between #31 Pin and #32 Pin) #1 Pin [E] #2 Pin [F] #31 Pin [G] #32 Pin [H]

POWR CRANKCASE. 4. Remove: Dowel pins

POWR CRANKCASE. 4. Remove: Dowel pins CRANKCAS 4. Remove: Dowel pins Crankcase inspection 1. Thoroughly wash the crankcase halves in a mild solvent. 2. Thoroughly clean all the gasket surfaces and crankcase mating surfaces. 3. Check: Crankcase