Cam Chain Replacement
1 - Drain the oil and coolant
2 - Remove...
CAM CHAIN AND TENSIONERS
4 - Remove...
RIGHT SIDE ENGINE COVER
7 - Remove...
UNDER THE ENGINE COVER
10 - Remove...
|Use an impact driver to remove the clutch. The 2X4 between the tire and swingarm holds the output shaft for the torque wrench on reassembly.
|Use an Impact hammer to remove the oil pump. There are two flat seal between the pump and the case.
|Two different size allen wrenches are req'd to remove the cam chain guides. Remove the guide so you don't have to remove the primary gear.
UNDER THE ENGINE COVER - CAM CHAIN
1 - Check your TDC on the flywheel now
2 - Drop the new chain from the top of the head to the crank sprocket and install it on the sprocket
3 - Install the intake cam to hang the chain from a spocket
|Clean your oil screen at the bottom of the case. I took the time to shim the new idler gear so I could spin the outer shim and circlip freely with my finger.
|I hung the chain on the two camshafts and placed it on the camshaft sprocket. The front (right) plastic guide will install by dropping in from the top. The rear (left) plastic guide will install by pushing it up from the bottom.
4 - Clean the threads in the case for the chain guide bolts
5 - Install right cam chain guide and Lock-Tite the 6mm bolt from the top down
6 - Switch cams (or wire the chain up) and install the left cam chain guide, from the bottom up, and Lock-Tite the 6mm allen bolt in place
7 - Install both cams with IN on the intake and EX lines on the outside of the sprockets level with the head
8 - Count the 32 pins and set the cams
9 - Install the the bottom spring tensioner (17mm bolt, spring and washer)
10 - Verify TDC on the flywheel again and check your cam sprocket marks per Step 7
11 - Install the cast camshaft top with four finger tight bolts
12 - The intake cam should be at about 1 o'clock with the flywheel at TDC
13 - Install the auto cam chain tensioner per the manual -- Retract the plunger, insert the body of the tensioner, set the 2-6mm bolts, drop in the spring, and install the 12mm hollow bolt
14 - Check your settings and torque down the cast camshaft top
UNDER THE ENGINE COVER - OIL PUMP
1 - Install the three #3 Phillips screws
2 - An 'O' ring is located under the 8 o'clock flat of the casting
3 - Both 'O' rings have a flat side. The flat side should face the engine as you install the pump. The second 'O' ring flat side face the pump as you install the outer cover
4 - Clean the 3 thread hole with contact cleaner. I used Lock-Tite to install the screws
5 - The bottom screw must be installed 1st the pump screwed down to within 1/4" before you seat it and install the other 2 screws
6 - Tighten screws with the impact driver and a #3 Phillips bit
UNDER THE ENGINE COVER - CLUTCH
1 - Deflate the rear tire and install a 2X4 between the swingarm and the tire
2 - Inflate rear tire with 50 to 60 psi
3 - Replace clutch assembly
4 - Put the tranny in 6th gear and torque to specs with a 22mm socket
5 - Replace the throw bearing
ENGINE COVER REPLACEMENT
1 - Set hollow guides and new gasket with grease
2 - Line up the flat in the clutch linkage parallel with the throw bearing face
3 - Install the cover and align the hollow guide pins, kick start shaft and pump output shaft
4 - Seat cover install perimeter bolts with anti-seize
5 - Cross tighten and torque bolts
6 - Install impeller with a 12mm socket
7 - Apply the gasket and replace the impeller cover