Camshaft Installation
SAFETY FIRST: Protective gloves and eyewear are recommended at this point.
Installation
Rocker Arms
Lubricate the inside diameter of the rocker arms and the outside diameter of the rocker arm shaft pivot sections with fresh engine oil.
Fit the rocker arms into their original locations.
Apply Blue Loctite to the threads of the rocker arm shafts. Install the rocker arm shafts and washers.
Tighten the rocker arm shafts to specification with a 10 mm Allen.
Item Thread dia. (mm) Torque kgf-m (N-m, lbf-ft)
Rocker arm shaft 18 4.5 (45, 32)
Camshafts
Position the piston at TDC as with removal. See the Camshaft topic for more information. Align the "T" mark on the flywheel with the index mark on the right crankcase cover. This shows the piston is at Top Dead Center.
Apply molybdenum oil to the camshaft lobes, the journal holders in the camshaft holders and the cylinder head.
Molybdenum oil: a mixture of molybdenum grease and fresh engine oil in a 50:50 ratio.
Fit the camshafts into place. Note the exhaust camshaft has a decompressor cam and intake camshaft doesn't.
Position the camshafts so that the punch marks on the end are pointing up. Minimize the amount of slack in the cam chain between the camshaft sprockets. The lines on the camshaft sprockets must align with the cylinder head cover mating surface as shown.
Double check the timing after the cam chain tensioner is installed.
Install the exhaust camshaft holder with he two dowel pins. Note the exhaust camshaft holder has the stopper pin.
Fit the intake camshaft holder into place with the two dowel pins.
Lubricate the threads of the camshaft holder bolts with fresh engine oil.
Insert the four largest camshaft holder bolts with new washers.
Position the four large cylinder head bolts as shown.
Insert the intake and exhaust camshaft holder bolts. Wait to install the cam chain side camshaft holder and bolts.
Long: 8 X 210 mm
Medium: 8 X 137 mm
Short: 8 X 71 mm
Tighten the bolts 1 - 9 in multiple steps in a crisscross pattern as shown below. Tighten the large bolts with a 14 mm socket and the smaller bolts with a 12 mm socket.
Camshaft Holder / Cylinder Head Bolt Torque
kgf-m (N-m, ft-lb)
Bolts 1, 2, 3, 4 5, 6, 7, 8, 9 10, 11, 12, 13
Step 1 2.4 (24, 17) 1.2 (12, 9)
Step 2 3.8 (38, 27) 2.3 (23, 17)
Step 3 4.8 (48, 35)
Step 4 1.2 (12, 9)
Step 5 2.3 (23, 17)
The cylinder head bolt is number 9.
Fit the cam chain side camshaft holder into place.
The arrow on the camshaft holder must face out.
Tighten the 10 - 13 bolts to specification with a 12 mm socket in multiple steps as indicated.
Camshaft Holder / Cylinder Head Bolt Torque
kgf-m (N-m, ft-lb)
Bolts 10, 11, 12, 13
Step 4 1.2 (12, 9)
Step 5 2.3 (23, 17)
Fit the upper cam chain guide into place.
Install the two cam chain guide bolts and tighten them securely with an 8 mm socket.
Cam Chain Tensioner
Make sure the cam chain tensioner mating surface is clean. Install a new gasket with the cam chain tensioner.
Use a small flat blade screwdriver to wind in the cam chain tensioner rod. Hold the screwdriver in place until both tensioner mounting bolts have been installed.
Install the two cam chain tensioner mounting bolts and tighten them to specification with an 8 mm socket. Install a new O-ring.
Item Thread dia. (mm) Torque kgf-m (N-m, ft-lb)
Cam chain tensioner bolt 6 1.2 (12, 8.6)
Install the cam chain tensioner sealing bolt and tighten it to specification with a 10 mm socket.
Item Thread dia. (mm) Torque kgf-m (N-m, ft-lb)
Tensioner sealing bolt 10 1 (10, 7.2)
Adjust the valve clearance. See the Valve Adjustment topic for more information.
Install the recoil starter cover.
Tighten the recoil starter bolts securely with an 8 mm socket.
Install the timing cap on the right side of the engine and tighten securely with a flat blade screwdriver.
Install the cylinder head cover. See the Cylinder Head Cover topic for more information.
Install the spark plug. See the Spark Plug topic for more information.
Install the right floor board. See the Floor Covers topic for more
