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:

Parts Location
1. Timing Rotor 2. Crankshaft Sensor 3. Horn 4. Oil Pressure Switch 5. Rear Brake Light Switch 6. Oxygen Sensor (Equipped Models) 7. Alternator 8. Stator Coil 9. Gear Position Switch 10. Sidestand Switch 11. Immobilizer Amplifier (Equipped Models) 12. Radiator Fan Motor 1 ...

Rider’s Seat Installation
Insert the tabs on the front of the rider’s seat into the slots in the frame and secure the seat with mounting bolts. Install the seat cover and bolts. A. Rider’s Seat B. Tabs C. Slots D. Stays ...

Rear Brake Pad Installation
Check that the pad spring is in place on the caliper. Push the caliper piston in as far as it will go. Install the piston side pad [A] first, and then another pad. Fit the brake pad end into the recess [B] of the caliper holder. Install the pad pin and the plug. Tighten: Torque - ...