Cam Chain Replacement
by Burnrider
FRAME
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...
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
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
FRAME
Install...