Kawasaki J300 - Service manual > Camshaft

Camshaft Removal

• Remove:
  Camshaft Sprocket (see Camshaft Sprocket Removal)
  Rocker Arms (see Rocker Arm Removal)
  Camshaft [A]

Camshaft Installation

• Clean the camshaft with the high flash-point solvent.
• Apply molybdenum disulfide oil solution to all cam parts, journal and bearing.
• Install the camshaft into the cylinder head.
• Install the removed parts (see appropriate chapters).
  • Check and adjust the valve clearance (see Valve Clearance Inspection in the Periodic Maintenance chapter).

Cam Wear Inspection

• Remove the camshaft (see Camshaft Removal).
• Measure the height [A] of each cam with a micrometer.

  If the cams are worn down past the standard, replace the camshaft.

Cam Height
 Standard:
  Exhaust 34.1721 mm (1.34535 in.)
  Intake 34.2987 mm (1.35033 in.)

Camshaft Bearing Inspection

• Visually inspect each camshaft bearing [A].

  If there is any damage, replace the camshaft.

• Turn the bearing back and forth while checking for roughness or binding.

  If roughness or binding is found, replace the camshaft.

  If it is noisy, does not spin smoothly, or has any rough spots, replace the camshaft.

Camshaft Sprocket Removal

• Bring the piston to the TDC of the compression stroke (see Valve Clearance Inspection in the Periodic Maintenance chapter).
• Remove:
  Right Side Fairing (see Side Fairing Removal in the Frame chapter)
  Cylinder Head Cover (see Cylinder Head Cover Removal)
  Camshaft Chain Tensioner (see Camshaft Chain Tensioner Removal)
  Camshaft Sprocket Bolts [A]
  Camshaft Sprocket [B]

NOTICE Always strain the camshaft chain while turning the crankshaft when the camshaft chain is loose. This avoids kinking the chain on the camshaft chain drive sprocket. A kinked chain could damage both the chain and the sprocket.

Camshaft Sprocket Installation

• Bring the piston to the TDC of the compression stroke (see Valve Clearance Inspection in the Periodic Maintenance chapter).
• Engage the camshaft chain with the camshaft sprocket.
  • Set the projection [A] of the camshaft facing front.
  • Align the timing marks [B] on the camshaft sprocket with the cylinder head upper surface [C].
• Apply a non-permanent locking agent to the threads of the camshaft sprocket bolts [D] and tighten them.

  Torque - Camshaft Sprocket Bolts: 12 N*m (1.2 kgf*m, 106 in*lb)

• Install the camshaft chain tensioner (see Camshaft Chain Tensioner Installation).
• Turn the crankshaft 2 turns clockwise to allow the tensioner to expand and recheck the camshaft chain timing.

NOTICE Rotation of the crankshaft with improper camshaft timing could cause the valve to contact each other or the piston, and bend. If any resistance is felt when turning the crankshaft, stop immediately, and check the camshaft chain timing.

• Install the removed parts (see appropriate chapters).

Camshaft Chain Removal

• Remove:
  Camshaft Sprocket (see Camshaft Sprocket Removal)
  Oil Pump Drive Chain (see Oil Pump Removal in the Engine Lubrication System chapter)
  Upper Camshaft Chain Guide Bolt [A]
  Upper Camshaft Chain Guide [B]
  Camshaft Chain [C]

Camshaft Chain Installation

• Installation is the reverse of removal.

  Torque - Upper Camshaft Chain Guide Bolt: 9.8 N*m (1.0 kgf*m, 87 in*lb)

Camshaft Chain Guide Wear Inspection

• Visually inspect the guides.

  If the guide is damaged, replace the guide.

See also: