Camshaft Installation

Remove the ignition pulse generator rotor cover cap.

(1) IGNITION

Align, the T mark (notch mark) with the index mark on the ignition pulse generator rotor cover by turning the crankShaft clockwise.

Apply molybdenum disulfide oil (a 50/50 mixture of engine oil and molybdenum disulfide grease) to the cam shaft journals of the cylider head and camshaft holders.

Crankshaft And Camshaft Generator

(1) INTAKE CAMSHAFT

(2) IDENTIFICATION MARKS

Zzr 1100 Camshaft Installation Timing
(3) EXHAUST CAMSHAFT

■ Install each camshaft to the correct side Each camshaft has an identification mark; "IN" is for the intake side and "EX" is for the exhaust side

Install the camshafts onto the cylinder head with the cam lobes for the No. 1 cylinder facing up as shown

(1) INTAKE CAMSHAFT

(2) IDENTIFICATION MARKS

PULSE GENERATOR COVER

PULSE GENERATOR COVER

MARK (2) INDEX MARK

MARK (2) INDEX MARK

Install the camshaft holders onto the camshafts.

Install the longer bolts into the outer bolt holes and the shorter ones into the inner, and tighten the camshaft holder bolts in the numerical order casted on the camshaft holders.

CAUTION

Do not tighten the camshaft holder bolts at this time. Tightening the camshaft holder bolts on only one-side might cause a camshaft holder to break.

Make sure that the T mark (notch mark) aligns with the index mark on the ignition pulse generator rotor cover.

install the cam chain over the cam sprockets. Install the cam sprockets onto the camshaft flange with the timing marks on the cam sprockets aligning with the cylinder head upper surface, facing opposite each other.

NOTE

• Install each cam sprocket to the correct camshaft Each cam sprocket has an identification mark; "IN" is for the intake side and "EX" is for the exhaust side,

Kawasaki Zzr1100 Timing

Before tightening the bolts, clean the locking agent off the bolt threads and the bolt holes in the cam sprockets.

Apply a locking agent to the threads of the cam sprocket bolts and tighten the two bolts loosely. Turn the crankshaft clockwise 1/2 turn (180") and tighten the other two bolts to the specified torque.

Turn the crankshaft clockwise 1/2 turn (180") and tighten the other two bolts to the specified torque.

Zzr1100 Timing Index

Install the cam chain cover and secure it with the bolts.

(1) CAMSHAFT

HOLDERS (2) BOLT

(1) CAMSHAFT

HOLDERS (2) BOLT

Submerge the camchain tensioner incleanerigineoil. Fill the cam chain tensioner with engine oil by pumping it until air bubbles stop coming out.

(1 ) CAM CHAIN TENSIONER

(2) CLEAN ENGINE OIL

Install a new gasket onto the cam chain tensioner in the direction shown. If it is installed incorrectly, there will be too much oil pressure against the tensioner.

CAUTION _

* 11 the gasket is installed incorrectly, the cam chain tensioner will wear out prematurely.

(1) This side against crankcase.

(2) This side against cam chain tensioner

Install the cam chain tensioner and new sealing washers, and tighten the bolts gradually in a criss cross pattern.

After installing the cam chain tensioner, make sure the timing marks on the cam sprockets align with the cylinder head upper surface while facing opposile each other.

Install the cylinder head cover (page 8-3}

Cylinder Head Removal/Installation

Requisite Service

• Exhaust system removal/installation(page 2-10} * Camshaft removal/installation (page 8-2)

Procedure

Q'ty

Remarks

Removal Order

Installation is in the reverse order of removal

11)

Cylinder head bolt (6mm)

2

From the outside to the inside, loosen the bolts in a

(2)

Cylinder head bolt (9mm)/Sealing washer

10/10

crisscross pattern in several steps.

(3)

Cylinder head assembly

1

Suspend the cam chain with a piece of wire to prevent

the chain from falling into the crankcase.

(4)

Gasket

1

(5)

Dowel pin

2

(6)

Cap nut

1

(7)

Sealing washer

1

(8)

Cam chain lensioner slider

1

Cylinder Head Disassembly/Assembly

NOTE

Store the valve components in the same order they were installed so they can be reinstalled in their or original locations. Refer to section 9 of the Common Service Manual for valve guide inspection/replacement.

Requisite Service

- Cylinder head removal/installation (page 8-7}

Procedure

Q'ty

Remarks

Removal Order

Installation is In the reverse order of removal-

(1)

Valve lifter

* Remove the valve litters using a hand lapping tool. Do not damage the cylinder head-valve lifter sliding surfaces.

(2)

Valve shirn

16

(3)

Valve cotter

32

Refer to page 8-9 for removal/installation.

(4)

Retainer

16

15)

Outer valve spring

-Install the valve springs with the narrow pitch end facing

16)

Inner valve spring

te-1

down

(7}

Intake valve

-using a marker, mark the valve guide with 8 line at the correct height as specified below, -chill the guides drive in the valve guide as shown to the line, -check the projection height with calipers to verify they are within specification.

(8)

Exhaust valve

a

(9)

Stem seal

16

(10)

Inner spring seat

16

(11)

Outer spring seat

16

(12)

Valve guide

16

Valve Cotters Removal/Installation

Remove the valve lifters and shims. NOTE

Do not allow shims to fall into the crankcase. The shim(s| may occasionally stick to the valve lifter. Mark the positions of all valve lifters and shims to ensure correct reassembly.

It is easy to remove the valve lifter with a valve lapping tool or magnet

Remove the shims with tweezers or a magnet.

Install the tappet hole protector into the valve lifter sliding surface.

07HMG-MR70002

Tappet hole protector

An equivalent tool can easily be made from a plastic 35mm film container by using the measurements shown below

An equivalent tool can easily be made from a plastic 35mm film container by using the measurements shown below

(1) VALVE SPRING COMPRESSOR

(2) ATTACHMENT

(1) VALVE SPRING COMPRESSOR

(2) ATTACHMENT

Install the valve spring compressor onto the valve and compress the valve spring.

CAUTION

■ Do not compress the valve springs more than necessary to remove the valve cotters or they might be fatigued

Remove (or install) the valve cotters.

Valve spring compressor attachment 07959-K.M30101 Valve spring compressor 07757- 0010000

(1) TAPPET HOLE PROTECTOR

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Responses

  • Anne
    How to install cam sprocket cbr 600?
    4 years ago
  • jose mcintyre
    How to align pulse generator rotor with out T marking?
    4 years ago
  • edwin
    How to remove ignition timing sprocket on cbr?
    4 years ago

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