Kawasaki Ninja Service Manual: 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.

• Install the camshaft sprockets as shown in the figure.

  #4 Cam Positions [A] Intake Camshaft Sprocket [B] Exhaust Camshaft Sprocket [C]

The intake 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 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 timing rotor bolt [A], turn the crankshaft clockwise until the line [B] (TDC mark for #1,4 pistons) on the timing rotor [C] is aligned with the mating surface [D] of the crankcase.

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.

• Pull the tension side (exhaust side) [A] of the chain taut to install the chain.
• Engage the camshaft chain with the sprockets so that timingmarks 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] #28 Pin [G] #29 Pin [H]

• Check that the timing marks [A] are securely aligned.

• Install the ten dowel pins on the marks [A].
• Install the camshaft cap, following the identification No.

  [B] and upper camshaft chain guide [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 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)

• Install the camshaft chain tensioner (see Camshaft Chain Tensioner Installation).
• Turn the crankshaft 2 turns clockwise to allow the tensioner to expand and recheck the camshaft chain timing.
• Install the removed parts (see appropriate chapters).