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ENGINE
77
2. Turn the crankshaft (with the 17 mm bolt
on the right end ofthe crankshaft) until the "T"
mark next to the No.
1
and No. 4
"F"
mark
aligns with the fixed pointer (Figure 18).
Number 1 and 4 pistons are now at top dead
center (TDC).
CA UTION
Do not use the small lnner bolt to turn
the englne or you wrll damage the
lgnltlon advance rnechanlsm.
3. Remove the 16 bolts securing the camshaft
caps (Figure 19). Gently tap the caps with a soft
mallet to loosen them and lift them off. There is
a hollow dowel pin at each cap.
4. Remove the camshafts. Tie the cam chain
up
to the frame with wire or place a tool
through the chain loop to keep itfrom falling
into the crankcase.
CAUTION
I f
the crankshaft tnlrst be rotated when
the cam chaln
I S
offthesprockets, pull up
on [he cam chaln and keep rt taut whde
turning
the crankshaft.
If
the cham is
slack, ~t may jam up at the crankshaft
and damage the chain and the sprocket.
CAUTION
Do
not install the camshafts on a
cvl~nder head that has been retnoved
fiotn the engine. You may bend the
~ulves and the carns must be removed
bclfore installing the cylinder head.
Camshaft Inspection
NOTE
Camshgfr journal/bearing surface
clearance is measured with Plastigage
while installing the camshafts. See
Camshafr Installation.
1. Check t h e camshaft journal outside
diameters (OD) for wear and scoring (A, Figure
20). If any journal outside diameter is smaller
than the wear limit in Table 1, install a new
camshaft.
2. Measure the cam lobe height (Figure 21).
Replace the camshaft if any lobe height is less
than the wear limit in Table 1. The lobes
should not be scored and the edges should be
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   Also See for Kawasaki KZ500

This manual is also suitable for:

Zx550Kz550Kzx550

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