Installation

1. Checktheconditionofthecamcoversealandcamcoverboltseals.Replaceasnecessary.

2. Applysiliconesealanttothecylinderheadwherefour'D'sectionsofthecamcover sealfit.

1.'D'sections

3.Fitthesealensuringthefour'D'sectionsseatinthecorrespondinghalf-roundsinthecylinderhead.Positionthesparkplugtowersealstothesixplugtowers.

4. Fitthecamcovertothecylinderhead.Ensurethatthesealremainsinposition,payingparticularattentiontothesixsparkplugtowerareas.

5. Fitthecamcoverbolts,completewiththeirseals(steelringsidefacingupwards)andtightentofingertight.

6. Progressivelyandevenlytightenthecamcoverboltsto1ONm.

7. Refitthecoilbracketandcoils.

8. Reattachtheplugleadstotheplugs.

9. Refittheintakeductbracket,tighteningitsboltsto9Nm.

10. Refittheintakeduct(seepage11.109).

11. Seatthefueltankontheframeandsecureit(seepage11.99).

12. Reconnectthebattery,positive(red)leadfirst.

13. Refittherider'sseat.

CamChainTensioner

Removal

1. Removethecamcover(seepage3.5).

2. Removetheinspectionplugfromtheclutchcover.

1.Inspectionplug

3.Turntheengineuntilthemaximumnumbersofcamlobesarefacingawayfromthevalves.Thiswillpreventthecamsfromspringingaroundwhenthecamchaintensionerisremoved.

1

cbps

1.Camshafts

2. Lobes

3. Valves

4. Removethecenternutandwasherfromthecamchaintensioner.

6. ServiceManual-RocketIll

Installation

1. Fitanewgaskettothetensionerbody.

2.Setthetensionerplungerontothefirsttoothoftheratchetbymanuallyliftingthetensionerpawlandpushingtheplungerintothetensionerbody.

5. Withdrawthespringandnutfromthetensionerbody.

1. Camchaintensioner

2. Centrenut

6. Removethecamchaintensionerbodyfromthehead.

Inspection

1. Inspectthetensionerspringfordamageanddeformation.Renewasnecessary.

2. Inspectthetipofthetensionerplungerforwearanddamage.Renewasnecessary.

1.Tensioner

2.Tensionerplunger

3.Pawl

3.Lookintotheinspectionhole.Rotatethecrankshaftclockwise(asviewedfromthefront),untilNo.1cylinderisatTDC.No.1cylinderisatTDCwhena'dot'markonthecrankgearisinalignmentwiththelineinthe uppercrankcase.

1. Crankshaft'dot'mark

2. Uppercrankcaseline

• ServiceManual-RocketIll

3.7

Inaddition,timingmarksonthecamshaftsprocketsshouldpointdownwardsat apointlevelwiththecylinderhead.Iftheydonotalignasshown,turnthecamshaftsuntiltheydoalign.

1. Inletcamtimingmarks

2. Exhaustcamlimingmarks

4.FitthedowelsoftoolT3880202tolocationholesinthecamsprockets,asshowninthediagrambelow.Thiswillholdthecamsinthecorrecttiming positionandpreventthemfromturningwhile thechaintensionerisfitted.

1. ToolT3880202

2. Camsprocketholes

5. Fitthetensionertothecrankcase(ratchetteethfacingupwards)ensuringthegasketisnotdamagedduringtheprocess.

6. Fitandtightenthetensionerfixingsto9Nm.

7. Pushthetensionerplungerintocontactwiththechainguideusingfingerpressure.

1.Tensioner

5. Fita newwashertothetensioner'scentrenut.

6. Fitthespringtothetensionerbody. Fitthecentrenutand tightento23Nm.

5. RemovetoolT3880202andturnthecrankshaftclockwise(asviewedfromthefrontoftheengine)throughfourcompleterevolutions.Stopwhenthetimingmarksonthecrankshaftgearrealignwith thelineintheupper crankcase.

1. Crankshaft'dot'mark

2. Uppercrankcaseline

11. Checkthat the camshaft marks alignasdescribed previously.Rectifyasnecessary.