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Kawasaki KZ1300-A1 Quick Reference Manual Page 66

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DISASSEMBLY--ENGINE INSTALLED
A.
Projection
B. Apply liquid gasket.
2.
Before installing
the
cylinder head cover
in
place,
make
sure
that there
is the
knock pin
in front
of
the
tachometer worm gear.
3.
Tighten
the cylinder head cover bolts
(32) to 1.5
kg-m
(11.0 ft-Ibs) of
torque,
and
the air
suction
valve
cover bolts
(6)
to 0.80 kg-m (69 in-Ibs)
of torque.
The four bolts which go
through the rubber plugs
are 5 mm longer than the others.
4.
Thoroughly warm up the engine, wait until
the engine
grows cold, and retighten
the
cover bolts
to the
specified torque.
5. Tighten the tachometer pinion holder Allen
bolt to
0.90 kg-m (78
in-Ibs)
of
torque.
CAMSHAFTS
Removal:
eRemove the fuel tank (Pg. 46).
eDisconnect the battery ground (-)
lead.
eRemove all the spark plugs.
eRemove the alternator cover (Pg.85). The
cover
need
not be removed completely
from
the crankcase, so
alternator leads may be left connected.
eUsing
a wrench
on
the alternator rotor
bolt,
turn the
crankshaft
until the
"T"
mark
on the rotor is
aligned
with the crankcase
mating
surface
on
the front side of
the
rotor.
At
this
point,
the
pistons
#1 and #fJ are at
top
dead
center
(TDe).
A.
"T" Mark
B. Mating Surface
eRemove
the
vacuum switch valve (Pg. 48).
eRemove the
two
lower
ignition
coils (Pg.
49).
eRemove the cylinder head cover
(Pg.
65).
eCut out a
cover from
a
rubber
plate using the pattern
on
Pg.
281,
and stuff it
in the camshaft
chain tunnel
so
that
no parts will fall
into the
crankcase.
eRemove
the
solenoid
fuel
valve (Pg.
46).
eRemove
the camshaft
chain
tensioner
(Pg. 60)
.
eRemove
the camshaft cap
bolts
(16), and
take off the
camshaft
caps
(8).
A. Camshaft Caps
C. Inlet Camshaft
B. Exhaust Camshaft
eRemove
the camshafts.
Use
a screwdriver
or wire
to keep the
chain
from falling
down
into the cylinder
block.
~ ;~~~~s t~~" ~~:ingca:t~::a C~:i~kS~:~
while the camshaft chain
is
loose, to avoid kinking the
chain on the
lower
(secondary shaft)
sprocket.
A kinked
chain could damage the chain and sprocket.
Installation:
e<::heck
that the cylinder head cover gasket
and
four
rubber plugs
are removed, all shims are
properly
fitted
in the valve lifter, and
all knock pins
(16)
of
the cam-
shaft
caps are installed.
e<::heck
crankshaft position to see that pistons #1 and
#fJ
are still
at
TDC (Fig. E78),
and
readjust jf nec-
essary.
Remember
to
pull
the
camshaft
chain taut
before
rotating
the
crankshaft.
eApply
clean engine oil to all cam
parts.
If
the
camshaft(s) and/or cylinder
head are
replaced with
new
ones,
apply a thin coat of a
molybdenum
disul-
fide
engine assembly
grease on
the new cam
part
surfaces.
e<::heck
to see that the camshaft chain is engaged with
the
lower
(secondary shaft) sprocket, and keep it
taut.
66

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