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:

Exhaust Butterfly Valve Actuator Removal
NOTICE Never drop the exhaust butterfly valve actuator especially on a hard surface. Such a shock to the actuator can damage it. Remove: Front Seat (see Front Seat Removal in the Frame chapter) Clamp [A] Screws [B] and Washers Slide the covers [A] and loosen the lock nuts [B] ...

US, CA and CAL Models
1. Hold the water hose [A]. Insert the tab into the slot. 2. Hold the water hose [B]. Insert the tab into the slot. 3. Water Hose Fitting on Cylinder Head 4. Heat Insulation Rubber Plate 5. Run the crankshaft sensor lead and the oil pressure switch lead into the slot, and hook the slot on ...

DFI Power Source
ECU Fuse Removal Refer to the 30 A Main/15 A ECU Fuse Removal in the Electrical System chapter. ECU Fuse Installation If a fuse fails during operation, inspect the DFI system to determine the cause, and then replace it with a new fuse of proper amperage. Refer to the Fuse Installation in ...