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

_• 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-

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.}

_• 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.

Camshaft Journal, Camshaft Cap Clearance

Standard: 0.028  0.071 mm (0.0011  0.0028 in.)

Service Limit: 0.16 mm (0.0063 in.)

If any clearance exceeds the service limit, measure the diameter of each camshaft journal with a micrometer.

Camshaft Journal Diameter

Standard: 23.950  23.972 mm (0.9429  0.9438 in.)

Service Limit: 23.92 mm (0.942 in.)

If the camshaft journal diameter is less than the service limit, replace the camshaft with a new one and measure the clearance again.

If the clearance still remains out of the limit, replace the cylinder head unit.

Camshaft Runout

_• Remove the camshaft (see Camshaft Removal).

_• Set the camshaft in a camshaft alignment jig or on V

blocks.

_• Measure runout with a dial gauge at the specified place as shown.

If the runout exceeds the service limit, replace the shaft.

Camshaft Runout

Standard: TIR 0.02 mm (0.0008 in.) or less Service Limit: TIR 0.1 mm (0.004 in.)

Cam Wear

_• Remove the camshaft (see Camshaft Removal).

_• Measure the height [A] of each cam with a micrometer.

If the cams are worn down past the service limit, replace

the camshaft.

Cam Height Standard:

Exhaust 35.843  35.957 mm (1.4111  1.4156 in.)

Inlet 36.543  36.657 mm (1.4387  1.4432 in.)

Service Limit:

Exhaust 35.74 mm (1.4071 in.)