Warning - General - Stabilise Motorcycle

1. Check that the dot mark on the primary gear is still aligned with the line on the crankcase and the service tool T3880601 is installed. Ensure the crankshaft cannot rotate.
2. Ensure that the wedge fitted earlier is still holding the camshaft drive chain tensioner blade in contact with the camshaft drive chain.
3. Check that the camshaft alignment marks point inwards.
4. To set the hydraulic tensioner onto the first tooth of the ratchet (minimum extension) carry out the following:
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.
5. Hold the resister ring ends together and pull out the plunger.



Resister ring ends Plunger

6. Remove the spring.



Spring

7. While holding the resister ring in place, pour out the engine oil into a suitable container.
8. Ensure the resister ring is correctly located as shown in the illustration below.



Resister ring

9. Refit the spring.
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.
10. Hold the resister ends together and insert the plunger into the tensioner housing.
11. Place the tensioner in a soft jawed vice.
12. 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.



Resister ring Plunger Groove for snap ring Snap ring

13. 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.



Groove for snap ring Snap ring

14. Fit a new O-ring and gasket to the hydraulic tensioner.
15. Fit the tensioner to the cylinder head as noted for removal. Tighten the bolts to 8 Nm.
16. Remove the wedge, taking care not to move or damage the tensioner blade.
17. Remove the service tool T3880601.
18. 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.
19. Check that there is tension in the camshaft drive chain and the timing marks at the camshaft sprockets are correctly aligned.
note
After fitting to the engine, the hydraulic tensioner will be empty of engine oil. After starting the engine, the camshaft drive chain and tensioner blade will be noisy until full pressure is felt at the tensioner plunger. This could take up to 5 seconds.
20. Check that the tensioner plunger is correctly located in the middle of the camshaft drive chain tensioner blade when viewed from above.
21. Rotate the engine through 4 full revolutions, and reset number 1 cylinder to TDC. Ensure that the dot mark on the primary gear aligns with the line on the crankcase.



Dot mark Marker line

note
The alignment marks do not need to be perfectly in line to each other, they only need to be pointing to each other.
22. Check that the camshaft timing marks point as illustrated below.



Camshaft Alignment Marks

23. Re-check the tensioner plunger location against the camshaft drive chain tensioner blade.

Perform the following operations

Perform the following operations:

Camshaft Cover - Install L Series

• Camshaft Cover - Installation

Crankcase Right Hand Cover - Install L Series

• Crankcase Right Hand Cover - Installation