5-18 ENGINE TOP END

Camshaft, Camshaft Chain

Camshaft Removal

•Remove the cylinder head cover (see Cylinder Head Cover Removal).

•Remove the timing inspection cap [A] and starter clutch bolt cap [B] on the starter clutch cover [C].

•Using a wrench on the starter clutch bolt [A], turn the crankshaft clockwise until the line [B] (TDC mark for #1,4 pistons) on the starter clutch is aligned with the notches [C] in the edge of the timing inspection hole [D] in the starter clutch cover.

If the starter clutch cover was removed, perform the next procedure.

○Using a wrench on the starter clutch bolt [A], turn the crankshaft clockwise until the line [B] (TDC mark for #1,4 pistons) on the starter clutch [C] is aligned with the mating surface [D] of the crankcase.

ENGINE TOP END 5-19

Camshaft, Camshaft Chain

•Remove the camshaft chain tensioner (see Camshaft Chain Tensioner Removal).

•Loosen the upper camshaft chain guide bolts and camshaft cap bolts as shown sequence [1 20] in the figure, and remove them.

•Remove:

Upper Camshaft 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 Bolts [A] Camshaft Sprockets

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.

Camshaft Installation

NOTE

○The exhaust camshaft has a 2716 EX mark [A] and the inlet camshaft has a 2716 IN mark [B]. Be careful not to mix up these shafts.

5-20 ENGINE TOP END

Camshaft, Camshaft Chain

•Install the camshaft sprockets as shown in the figure. #4 Cam Positions [A]

Inlet Camshaft Sprocket [B] Exhaust Camshaft Sprocket [C]

○The inlet 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 [A] to all cam parts, journals and tappets.

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

•Using a wrench on the starter clutch bolt [A], turn the crankshaft clockwise until the line [B] (TDC mark for #1,4 pistons) on the starter clutch is aligned with the notches [C] in the edge of the timing inspection hole [D] in the starter 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.

If the starter clutch cover was removed, perform the next procedure.

○Using a wrench on the starter clutch bolt [A], turn the crankshaft clockwise until the line [B] (TDC mark for #1,4 pistons) on the starter clutch [C] is aligned with the mating surface [D] of the crankcase.

ENGINE TOP END 5-21

Camshaft, Camshaft Chain

•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]

#26 Pin [G]

#27 Pin [H]

•Apply molybdenum disulfide oil solution [A] to all cam lobes, journals and thrust journals.

5-22 ENGINE TOP END

Camshaft, Camshaft Chain

•Install: O-rings [A]

Dowel Pins [B] O-rings [C] Dowel Pins [D]

•Install the camshaft caps and upper camshaft chain guide [A] as shown in the figure.

“R” Mark [B]

“L” Mark [C]

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

Torque - Camshaft Camshaft Cap Bolts (1 10, 13 20):

First: 5.9 N·m (0.60 kgf·m, 52 in·lb) Final: 12 N·m (1.2 kgf·m, 106 in·lb)

Upper Camshaft Chain Guide Bolts (11, 12): First: 5.9 N·m (0.60 kgf·m, 52 in·lb) Final: 12 N·m (1.2 kgf·m, 106 in·lb)