Kawasaki Ninja Service Manual: Camshaft Installation

Kawasaki Ninja Service Manual / Engine Top End / Camshaft, Camshaft Chain / Camshaft Installation

NOTE

The exhaust camshaft has a 1001 EX mark [A] and the intake camshaft has a 3154 IN mark [B]. Be careful not to mix up these shafts.

Camshaft Installation


The intake camshaft sprocket and exhaust camshaft sprocket are identical

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

Camshaft Installation


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

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


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] #28 Pin [G] #29 Pin [H]

Camshaft Installation


Camshaft Installation


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)

Camshaft Installation


Camshaft Removal
Remove: Cylinder Head Cover (see Cylinder Head Cover Removal) Crankshaft Sensor Cover (see Crankshaft Sensor Removal in the Electrical System chapter) Using a wrench on the timing rotor bol ...

Camshaft, Camshaft Cap Wear Inspection
Remove the camshaft caps (see Camshaft Removal). Cut the strips of plastigage (press gauge) to journal width. Place a strip on each journal parallel to the camshaft installed in the correct ...

Other materials:

Cylinder (Upper Crankcase) Wear Inspection
Split the crankcase (see Crankcase Splitting). Remove the pistons (see Piston Removal). Assemble the cylinder (upper crankcase) [A], the cylinder head [B] and the cylinder head gasket [C]. Tighten the cylinder head bolts (see Cylinder Head Installation in the Engine Top End chapter). ...

Stopping the Motorcycle in an Emergency
Your Kawasaki Motorcycle has been designed and manufactured to provide you optimum safety and convenience. However, in order to fully benefit from Kawasaki’s safety engineering and craftsmanship, it is essential that you, the owner and operator, properly maintain your motorcycle and becom ...

Check 3-3: High Beam Indicator Light (LED) Inspection
Connect the leads in the same circuit as Check 3-2. Connect the terminal [7] to the battery (+) terminal. Check that the high beam indicator light (LED) [A] goes on. If the indicator light does not go on, replace the meter unit. ...