Camshaft Timing Adjust

Warning - General - Stabilise Motorcycle

warning
Make sure the motorcycle is stabilised and adequately supported.Do not support the motorcycle on any ancillary component, the exhaust system or any other non structural parts of the motorcycle frame.A correctly supported motorcycle will help prevent it from falling.An unstable motorcycle may fall resulting in motorcycle damage, serious injury or death.

Perform the following operations

Perform the following operations:

note
After the initial camshaft timing has been completed and T3880640 - Camshaft Timing Plate removed, it will not be possible to refit it without first loosening the camshafts.
caution
The camshaft sprockets are attached to the camshafts using slotted bolt holes. This allows for very accurate valve timing and therefore improved performance and fuel economy. Never fit the camshaft sprockets without correctly setting the valve timing using the service tools and timing procedure described below. Severe engine damage will result from incorrect camshaft adjustment.
note
The camshaft sprocket fixings need only be loosened sufficiently to allow the sprockets to rotate on the camshafts.Removing the spark plugs reduces compression resistance when turning the engine
  1. Remove the spark plugs to reduce compression resistance when turning the engine.
    2. note
    While rotating the crankshaft, ensure that the front camshaft drive chain rubbing blade remains in its mounting.Before inserting the timing pin, ensure the dot on the primary gear is aligned with the line on the crankcase.
  2. Using the bolt fitted to the end of the crankshaft, rotate the crankshaft clockwise (the normal direction of rotation). Stop rotation when the camshaft alignment marks are positioned outwards as shown below and the dot mark on the primary gear aligns with the line on the crankcase.
    3. camshaft alignment_gaaa_14

    1. Camshaft alignment marks

    2. Fixings

  3. Insert service tool T3880601 into the timing holes in the crankcase and crankshaft.
    4. Fit service tool 3880601 chwh

    1. DOT alignment mark

    2. Marker line

    3. T3880601 - Camshaft Timing Pin

    4. Timing hole in crankcase

  4. Evenly release the camshaft drive chain tensioner mounting bolts until the plungers spring tension has been released.
  5. Remove the tensioner and discard the O-ring and gasket.
    6. LG1 Tensioner

    1. Tensioner

    2. Fixings

  6. Fit the service tool T3880607 using the original fixings and tighten to 8 Nm.
    7. LG1 Tensioner Tool

    1. T3880607 - Camshaft Timing Tensioner

    caution
    The torque value stated is very important to accurate timing. Always use the correct value of 0.6 Nm, as set using the service tool T3880609. Using an incorrect torque value will result in incorrect valve timing being set, or damage to the tensioner blade or other valve train components.Either condition may result in serious damage to the engine, reduced engine performance, or reduced fuel economy.
  7. Using the service tool T3880609 and a 6 mm Ball Ended Allen Key, tighten the service tool T3880607 to 0.6 Nm preset by the service tool T3880609.
    8. LG1 Tensioner Tool Adapter

    1. T3880607 - Camshaft Timing Tensioner

    2. T3880609 - Timing Torque Limiter

    3. 6 mm Ball Ended Allen Key

    note
    Loosen the camshaft sprocket fixings just enough to allow the sprocket and camshaft to be able to move independently.
  8. Make sure there is no slack in the chain between the crankshaft and the sprockets.
  9. Loosen but do not remove the two accessible fixings.
    10. Camshaft sprocket fixings chei_1

    1. Fixings

  10. Remove service tool T3880601 from the crankcase and crankshaft.
    11. Fit service tool 3880601 chwh

    1. DOT alignment mark

    2. Marker line

    3. T3880601 - Camshaft Timing Pin

    4. Timing hole in crankcase

  11. Using the bolt fitted to the end of the crankshaft, rotate the crankshaft 360° clockwise (the normal direction of rotation). Stop rotation when the camshaft alignment marks are positioned inwards as shown below and the dot mark on the primary gear aligns with the line on the crankcase.
  12. In addition to the crankshaft alignment mark, at TDC, the alignment marks on the camshaft bosses will point inwards.
    13. Camshaft alignment gaaa_12

    1. Camshaft alignment marks

    caution
    Do not rotate the engine further once the four camshaft sprocket bolts have been loosened. Rotation of the engine with the four sprocket bolts loose will result in valve to piston contact.Valve to piston contact will cause serious engine damage.
  13. Insert service tool T3880601 into the timing holes in the crankcase and crankshaft.
    14. Fit service tool 3880601 chwh

    1. DOT alignment mark

    2. Marker line

    3. T3880601 - Camshaft Timing Pin

    4. Timing hole in crankcase

    note
    Loosen the camshaft sprocket fixings just enough to allow the sprocket and camshaft to be able to move independently.
  14. Loosen but do not remove the remaining two fixings.
    15. Camshaft sprocket fixings chei_1

    1. Fixings

  15. Note the orientation of the camshaft ladder in relation to the cylinder head.
  16. Progressively release the fixings securing the camshaft ladder to the cylinder head in the sequence shown below.
    17. Camshaft ladder removal cdqs

    Camshaft Ladder Fixing Release Sequence

  17. Remove the camshaft ladder, top pad, dowels and spark plug tower O-rings, noting their orientation for installation.
    18. note
    Adjust the valve clearances as required using the data collected prior to removal of the camshafts (see Valve Clearance Adjustment).
    caution
    Make sure the service tool T3880640 removal screw is unscrewed fully.The service tool T3880640 must be positioned so that it is located centrally between the camshafts.Failure to fit the service tool T3880640 correctly may lead to the irreparable damage to the camshafts.
  18. Insert the service tool T3880640 into the camshaft slots as shown below.
    19. Remove camshaft timing plate choj

    1. T3880640 - Camshaft Timing Plate

    2. Camshaft slots

    3. Removal screw

    note
    Make sure the alignment marks on the camshaft bosses are pointing inwards.
  19. Rotate both sprockets on the camshafts until the fixings are positioned centrally within the slots.
    20. camshaft sprocket slots_gaaa_15

    1. Elongated slots

    2. Fixings

  20. Check that the chain is correctly located around the crankshaft, and both camshaft sprockets.
  21. Assemble the dowels, spark plug tower O-rings, camshaft ladder and top pad in the same location and orientation as prior to removal.
    22. note
    The bolts for the camshaft cap ladder are tightened in two stages.
  22. Stage 1 - Fit and evenly tighten the fixings to 5 Nm, in the sequence shown below.
    23. Camshaft ladder tightening sequence cdqr

    Camshaft Cover Fixings Tightening Sequence

  23. Stage 2 - Fit and evenly tighten the fixings to 10 Nm, in the sequence shown below.
    24. Camshaft ladder tightening sequence cdqr

    Camshaft Cover Fixings Tightening Sequence

    caution
    The torque value stated is very important to accurate timing. Always use the correct value of 0.6 Nm, as set using the service tool T3880609. Using an incorrect torque value will result in incorrect valve timing being set, or damage to the tensioner blade or other valve train components.Either condition may result in serious damage to the engine, reduced engine performance, or reduced fuel economy.
  24. Using the service tool T3880609 and a 6 mm Ball Ended Allen Key, tighten the service tool T3880607 to 0.6 Nm preset by the service tool T3880609.
    25. LG1 Tensioner Tool Adapter

    1. T3880607 - Camshaft Timing Tensioner

    2. T3880609 - Timing Torque Limiter

    3. 6 mm Ball Ended Allen Key

  25. Tighten the two accessible (uppermost) camshaft sprocket fixings to 22 Nm.
    26. Camshaft sprocket fixings chei_1

    1. Uppermost fixings

  26. Remove the service tool T3880640 by rotating the removal screw clockwise as shown below.
    27. Install camshaft timing plate choj_1

    1. T3880640 - Camshaft Timing Plate

    2. Removal screw

  27. Remove service tool T3880601 from the crankcase and crankshaft.
    28. Fit service tool 3880601 chwh

    1. DOT alignment mark

    2. Marker line

    3. T3880601 - Camshaft Timing Pin

    4. Timing hole in crankcase

  28. Rotate the crankshaft until the remaining two fixings are accessible.
  29. Make sure there is no slack between the crankshaft and exhaust sprocket when the sprocket fixings are centrally located within the slotted holes and the alignment marks on the end of the camshaft journals are pointing inwards.
    30. Camshaft alignment gaaa_12

    Camshaft Alignment Marks

  30. Tighten the two remaining (uppermost) camshaft sprocket fixings to 22 Nm.
    31. Camshaft sprocket fixings chei_1

    1. Uppermost fixings

  31. Check that the chain is correctly located around the crankshaft, and both camshaft sprockets.
    32. caution
    Always check that the service tool T3880640 has been removed before rotating the engine. Severe damage will result to the camshafts or service tool T3880640 if engine rotation is attempted with the tool installed.
  32. Set the hydraulic tensioner onto the first tooth of the ratchet (minimum extension) carry out the following:
    33. note
    If installing a new hydraulic tensioner, do not release the plunger before fitting.If installing the original hydraulic tensioner, the engine oil must be drained out of the tensioner to enable the plunger to be set onto the first tooth of the ratchet.Prior to installation the hydraulic tensioner must be set to the first tooth on the ratchet (minimum extension).
  33. Hold the resister ring ends together and pull out the plunger.
    34. Hold resister ring ends cfei_2

    1. Resister ring ends

    2. Plunger

  34. Remove the spring.
    35. Remove spring cfhp

    1. Spring

  35. While holding the resister ring in place, pour out the engine oil into a suitable container.
  36. Make sure the resister ring is correctly located as shown in the illustration below.
    37. Resister ring location cfho

    1. Resister ring

  37. Refit the spring.
    38. caution
    When resetting the tensioner, care must be taken to avoid activating the tensioner when there is no resistance on the plunger.Activating the tensioner when there is no resistance on the plunger may cause internal damage to the tensioner housing.It is recommended that the plunger is pushed into the tensioner housing in a controlled manner using a suitable soft jawed vice. Once the snap ring is located into its groove, the vice should be released slowly to ensure that the plunger is held in place.
  38. Hold the resister ends together and insert the plunger into the tensioner housing.
  39. Place the tensioner in a soft jawed vice.
  40. While holding the resister ends together, use the vice to push the plunger through the resister ring until the groove for the snap ring aligns with the snap ring.
    41. Refit plunger (cfei_3)

    1. Resister ring

    2. Plunger

    3. Groove for snap ring

    4. Snap ring

  41. When the groove aligns with the snap ring, release the resister ring and move one end of the snap ring into the groove. Slowly release the vice to ensure that the plunger is held in place.
    42. Snap ring to groove cfej

    1. Groove for snap ring

    2. Snap ring

  42. Place a suitable wedge between the camshaft drive chain tensioner blade and crankcase, to hold the camshaft drive chain taut during removal of the service tool T3880607.
    43. 9 mm spacer for timing tensioner install_chwh_1

    1. Wedge

    2. Crankcase

    3. Tensioner blade

  43. Release the tension on Camshaft Timing Tensioner T3880607and remove the T3880609 - Timing Torque Limiter .
    44. LG1 Tensioner Tool Adapter

    1. T3880607 - Camshaft Timing Tensioner

    2. T3880609 - Timing Torque Limiter

    3. 6 mm Ball Ended Allen Key

  44. Remove the T3880607 - Camshaft Timing Tensioner.
    45. LG1 Tensioner Tool

    1. T3880607 - Camshaft Timing Tensioner

  45. Fit the timing chain tensioner, incorporating a new gasket and O-ring. Tighten the fixings to 8 Nm.
    46. LG1 Tensioner

    1. Tensioner

    2. Fixings

  46. Remove the wedge from between the camshaft drive chain tensioner blade and crankcase.
  47. To release the hydraulic tensioner, rotate the crankshaft 1/4 of a turn anticlockwise using the bolt fitted to the end of the crankshaft. Then rotate the crankshaft clockwise two revolutions until the 'dot' mark on the primary gear aligns with the line on the crankcase.
    48. note
    Before inserting the timing pin, make sure the 'dot' on the primary gear is aligned with the line on the crankcase.
  48. Insert the service tool T3880601 into the timing holes in the crankcase and crankshaft.
    49. Fit service tool 3880601 chwh

    1. Dot mark

    2. Marker line

    3. T3880601 - Camshaft Timing Pin

    4. Timing hole in crankcase

  49. Check that the timing marks are still approximately aligned (to check that the camshaft timing has not moved during service tool T3880607 removal).
  50. Remove the service tool T3880601.

Perform the following operations

Perform the following operations: