Kawasaki Z1000SX - Service manual > Camshaft Removal

• Remove:
  Cylinder Head Cover (see Cylinder Head Cover Removal)
  Crankshaft Sensor Cover (see Crankshaft Sensor Removal in the Electrical System chapter)
• Turn the crankshaft clockwise, align the #1, 4 mark on the timing rotor with the crankcase timing mark.

  TDC mark [A] for #1, 4 Pistons Timing Mark (Crankcase Halves Mating Surface) [B]

• Remove the camshaft chain tensioner (see Camshaft Chain Tensioner Removal).
• Loosen the upper chain guide bolts and camshaft cap bolts as shown sequence [1 - 20] in the figure, and remove them.
• Remove:
  Upper Chain Guide [A]
  Camshaft Caps [B]
  Camshafts [C]
• Stuff a clean cloth into the chain tunnel to keep any parts from dropping into the crankcase.

• Remove:
  Camshaft Sprocket Mounting Bolts [A]
  Camshaft Sprockets [B]

NOTICE 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.

Camshaft Installation

• Be sure to install the following parts.

  Plug Hole Gaskets [A]
  Dowel Pins [B]

NOTE

• The exhaust camshaft has a 8943 EX mark [A] and the intake camshaft has a 8943 IN mark [B]. Be careful not to mix up these shafts.

• Install the camshaft sprockets so that position the timing marks [A] outside.
  • The intake camshaft sprocket and exhaust camshaft sprocket are identical.
• Apply a non-permanent locking agent to the threads of 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 cam parts and journals.

• Using a wrench on the timing rotor bolt [A], turn the crankshaft clockwise until the line [B] (TDC mark for #1,4 pistons) on the timing rotor is aligned with the timing mark [C] (Crankcase Halves Mating Surface).

NOTICE 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.

• Pull the tension side (exhaust side) [A] of the chain taut to install the chain.
• Engage the camshaft chain with the sprockets so that timing marks on the sprockets are positioned as shown in the figure.
  • The timing marks must be aligned with the cylinder head upper surface [B].
    EX mark [C]
    IN mark [D]
    #1 pin [E]
    #2 pin [F]
    #29 pin [G]
    #30 pin [H]

• Before installing the camshaft caps and upper chain guide, install the camshaft chain tensioner body temporarily (see Camshaft Chain Tensioner Installation).
• Install the camshaft caps and upper camshaft chain guide [A] as shown in the figure.

  Identification No. 1 - 4 (Camshaft Cap) [B]

• First tighten the all camshaft cap bolts and upper camshaft chain guide bolts evenly to seat the camshaft in place, then tighten all bolts following the specified tightening sequence.

  Torque -
   Camshaft Cap Bolts [1 - 18]: 12 N*m (1.2 kgf*m, 106 in*lb)
   Upper Camshaft Chain Guide Bolts [19, 20]: 12 N*m (1.2 kgf*m, 106 in*lb)

• Install the camshaft chain tensioner (see Camshaft Chain Tensioner Installation).
• Turn the crankshaft 2 turns clockwise to allow the tensioner to expand and recheck the camshaft chain timing.
• Install the cylinder head cover (see Cylinder Head Cover Installation).

See also: