How To: Install Cams

<body topmargin=0 leftmargin=0 marginheight=0 marginwidth=0> <table cellpadding=0 cellspacing=0 border=0 height="100%"><tr> <td valign="top" colspan=2 height=90 BGCOLOR="#333333" TEXT="#F7F7FF" bgproperties="fixed" background="184dcde1ddualp.png"> <div> How To:  Install Cams              <FONT SIZE="3" COLOR="#CCCC99" FACE="Times New Roman" ><A HREF="index.htm" TARGET="_top" TITLE="Kawasaki KFX 700 VForce Page"><U>home</U></A></FONT></div> <div> </div> </td> </tr><tr> <td valign="top" width=23.75% BGCOLOR="#333333" TEXT="#F7F7FF" background="184dedc2ddualp.png"> <bR> <div> <A HREF="faq.htm" TARGET="_top" TITLE="VForce FAQ"><U><B><IMG SRC="18ddc120.png" border=0 width="220" height="18" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></B></U></A></div> <div> <A HREF="tips.htm" TARGET="_top" TITLE="General VForce Tips"><U><B><IMG SRC="18edc120.png" border=0 width="220" height="18" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></B></U></A></div> <div> <A HREF="performance.htm" TARGET="_top" TITLE="Performance 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HREF="graphics.htm" TARGET="_top" TITLE="White Brothers Graphics Kit"><U><B><IMG SRC="200dc120.png" border=0 width="220" height="18" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></B></U></A></div> <div> <A HREF="decals.htm" TARGET="_top" TITLE="VForce Decals"><U><B><IMG SRC="252dc120.png" border=0 width="220" height="18" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></B></U></A></div> <div> <A HREF="coolers.htm" TARGET="_top" TITLE="20Fin Inline Coolers"><U><B><IMG SRC="201dc120.png" border=0 width="220" height="18" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></B></U></A></div> <bR> <div> <B>How To:</B></div> <div> <A HREF="cams.htm" TARGET="_top" TITLE="How To: Install Cams"><U><B><IMG SRC="244dc120.png" border=0 width="220" height="18" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></B></U></A></div> <div> <A HREF="beltchange.htm" TARGET="_top" TITLE="How To: Change Belt"><U><B><IMG SRC="287dc120.png" border=0 width="220" height="18" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></B></U></A></div> <div> <A HREF="primary.htm" TARGET="_top" TITLE="How To: Changing Primary Spring"><U><B><IMG SRC="19adc120.png" border=0 width="220" height="18" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></B></U></A></div> <div> <A HREF="weights.htm" TARGET="_top" TITLE="How To: Changing Clutch Weights"><U><B><IMG SRC="19fdc120.png" border=0 width="220" height="18" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></B></U></A></div> <div> <A HREF="mains.htm" TARGET="_top" TITLE="How To: Changing Main Jets"><U><B><IMG SRC="1a6dc120.png" border=0 width="220" height="18" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></B></U></A></div> <div> <A HREF="needles.htm" TARGET="_top" TITLE="How To: Shim Carb Needle"><U><B><IMG SRC="1a1dc120.png" border=0 width="220" height="18" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></B></U></A></div> <div> <A HREF="degreekey.htm" TARGET="_top" TITLE="How To: Install Degree Key"><U><B><IMG SRC="1a2dc120.png" border=0 width="220" height="18" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></B></U></A></div> <div> <A HREF="valves.htm" TARGET="_top" TITLE="How to: Adjust Valves"><U><B><IMG SRC="1a8dc120.png" border=0 width="220" height="18" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></B></U></A></div> <div> <A HREF="seatcover.htm" TARGET="_top" TITLE="How To: Install Seat Cover"><U><B><IMG SRC="1a9dc120.png" border=0 width="220" height="18" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></B></U></A></div> <div> <A HREF="wheelbearings.htm" TARGET="_top" TITLE="How To: Install Wheel Bearings"><U><B><IMG SRC="1eedc120.png" border=0 width="220" height="18" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></B></U></A></div> <div> <A HREF="synchronize.htm" TARGET="_top" TITLE="How To: Synchronize Carburetors"><U><B><IMG SRC="1aadc120.png" border=0 width="220" height="18" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></B></U></A></div> <div> <A HREF="swingarm.htm" TARGET="_top" TITLE="How To: Install Swingarm Bearings"><U><B><IMG SRC="1b1dc120.png" border=0 width="220" height="18" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></B></U></A></div> <div> <A HREF="repack.htm" TARGET="_top" TITLE="How To: Repack Exhaust"><U><B><U><IMG SRC="225dc120.png" border=0 width="220" height="18" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></U></B></U></A></div> <div> <A HREF="choke.htm" TARGET="_top" TITLE="How To: Fix Sticking Choke"><U><B><IMG SRC="286dc120.png" border=0 width="220" height="18" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></B></U></A></div> </td> <td valign="top" height=390 BGCOLOR="#FFFFFF" TEXT="#080000" background="18564643.png"> <bR> <bR> <bR> <div> <I><B>Follow the first 6 steps on the "Adjust Valves" page.</B></I></div> <div> <I><B>This consists of  removing the airbox plastic, the airbox, the battery, the Kawasaki logo cover, the timing inspection plug.  </B></I></div> <div> <I><B>Also remove the rubber splash guard in front of the airbox.</B></I></div> <div> <I><B>Turn the crankshaft bolt until you see the following in the inspection hole:</B></I></div> <bR> <bR> <bR> <div> <IMG SRC="15d80cc0.jpg" border=0 width="640" height="460" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></div> <bR> <bR> <div> <I><B>Remove the rocker case cover by removing these 10 bolts.</B></I></div> <div> <I><B> <IMG SRC="23080e00.jpg" border=0 width="640" height="480" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></B></I></div> <bR> <div> <I><B>Then remove the tappet covers & these 2 bolts inside.</B></I></div> <div> <I><B><IMG SRC="23180e00.jpg" border=0 width="640" height="480" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></B></I></div> <bR> <div> <I><B>Remove the cover.  </B></I><I><B><U>Make sure the lobes on the cam are pointing down</U></B></I><I><B>.</B></I></div> <div> <I><B><IMG SRC="23280e00.jpg" border=0 width="640" height="480" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></B></I></div> <div> <I><B>If the lobes are not pointing down, spin the crankshaft one full revolution until they are.</B></I></div> <bR> <div> <I><B>This is what you will see.  Note the lines on each side of the sprocket, they will line up evenly with the top of the head.</B></I></div> <div> <I><B><IMG SRC="23380e00.jpg" border=0 width="640" height="480" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></B></I></div> <div> <I><B>There will be an arrow in the middle of the sprocket pointing upwards.</B></I></div> <bR> <div> <I><B>Now remove the chain tensioner for the rear cam.</B></I></div> <div> <I><B><IMG SRC="23580e00.jpg" border=0 width="640" height="480" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></B></I></div> <div> <I><B>Remove the center bolt, the spring dowel and the spring.</B></I></div> <bR> <div> <I><B>Remove the 2 8mm bolts on each side.</B></I></div> <div> <I><B><IMG SRC="23480e00.jpg" border=0 width="640" height="480" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></B></I></div> <bR> <div> <I><B>Slide the assembly out and set it aside.</B></I></div> <div> <I><B><IMG SRC="23680e00.jpg" border=0 width="640" height="480" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></B></I></div> <bR> <bR> <div> <I><B>Lift up on the opposite side of the cam and work the chain from the sprocket.</B></I></div> <div> <I><B><IMG SRC="23780e00.jpg" border=0 width="640" height="480" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></B></I></div> <div> <I><B>Lift the cam out after the chain is off.  Wire up the chain so that it doesn't fall down inside the head.</B></I></div> <bR> <bR> <div> <I><B>Wrap the cam up to prevent scarring and put it in a vise.</B></I></div> <div> <I><B><IMG SRC="23880e00.jpg" border=0 width="640" height="480" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></B></I></div> <div> <I><B>Lightly tighten the vice and remove the allen-head bolts to detach the sprocket.</B></I></div> <bR> <div> <I><B>Sit the cams beside each other so you can tell which direction to mount the sprocket.</B></I></div> <div> <I><B><U>Make sure you have the correct cam</U></B></I><I><B>, front and rear are different.</B></I></div> <div> <I><B><IMG SRC="23a80e00.jpg" border=0 width="640" height="480" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></B></I></div> <div> <I><B>Bolt it on the new cam and use Loc-Tite on the allen bolts. </B></I></div> <bR> <bR> <div> <I><B>Coat the new cam with assembly lube</B></I></div> <div> <I><B><IMG SRC="23c80e00.jpg" border=0 width="640" height="480" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></B></I></div> <div> <I><B>Lift up on the back of the cam and work it back onto the chain</B></I></div> <bR> <bR> <div> <I><B>Make sure your marks line up with the top of the head & the arrow in the center is pointing up.</B></I></div> <div> <I><B><IMG SRC="23380e00.jpg" border=0 width="640" height="480" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></B></I></div> <bR> <bR> <div> <I><B>Coat the rocker cover with a </B></I><I><B><U>semi-drying sealant</U></B></I></div> <div> <I><B><IMG SRC="23d80e00.jpg" border=0 width="640" height="480" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></B></I></div> <div> <I><B>Kawasaki Bond or Yamabond 4</B></I></div> <bR> <bR> <div> <I><B>Push the stopper in and push the plunger all the way in to its loosest setting</B></I></div> <div> <I><B><IMG SRC="23e80e00.jpg" border=0 width="640" height="480" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></B></I></div> <bR> <bR> <div> <I><B>Re-install the tensioner assembly</B></I></div> <div> <I><B><IMG SRC="23f80e00.jpg" border=0 width="640" height="480" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></B></I></div> <div> <I><B>Put the pin into the spring and carefully install it back into place</B></I></div> <bR> <bR> <div> <I><B>Set your valves at .006 intake and .010 exhaust</B></I></div> <div> <IMG SRC="14f80e00.jpg" border=0 width="640" height="480" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></div> <div> <I><B>Put the tappet covers back on and start on the front.</B></I></div> <bR> <bR> <div> <I><B>To get at the bolts on the front remove the intake vent for the clutch</B></I></div> <div> <I><B><IMG SRC="24080e00.jpg" border=0 width="640" height="480" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></B></I></div> <bR> <bR> <div> <I><B>Spin the crankshaft until you have the front at TDC.</B></I></div> <div> <IMG SRC="15c80980.jpg" border=0 width="640" height="408" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></div> <div> <I><B>Once again, </B></I><I><B><U>make sure the lobes on the cam are pointing down.</U></B></I></div> <bR> <bR> <div> <I><B>Remove 12 bolts to get the front rocker cover off.</B></I></div> <div> <I><B><IMG SRC="24180e00.jpg" border=0 width="640" height="480" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></B></I></div> <div> <I><B>Don't forget the 2 under the tappet covers.</B></I></div> <bR> <bR> <div> <I><B>Remove the front tensioner assembly.</B></I></div> <div> <I><B><IMG SRC="24280e00.jpg" border=0 width="640" height="480" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></B></I></div> <bR> <div> <I><B>Everything else is the same as the rear.</B></I></div> <bR> <div> <I><B>Start it up and turn the idle up high, to at least 2000 RPM's.</B></I></div> <div> <I><B>Let it idle for 20 minutes at  high-RPM to break the cams in or take it for a 20-minute ride.</B></I></div> <div> <I><B>Change the oil and re-adjust the valves.</B></I></div> <bR> <bR> <bR> <bR> <bR> <div> <A HREF="dalton.htm" TARGET="_top" TITLE="Dalton Clutch Parts "><U><B><IMG SRC="1d996640.gif" border=0 width="150" height="100" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></B></U></A></div> <bR> <bR> <div> <I> <I> <a href="http://bar.hit-counter.udub.com/stats/k/kmartin173/" target="_top"><font color="#000000""><img border="0" alt="Free Hit Counters" src="http://bar.hit-counter.udub.com/counter/index.php?u=kmartin173&s=scoreboard" ALIGN="middle" HSPACE="4" VSPACE="2"></font></a><br><a href="http://home-loans.udub.com/" target="_top"><font color="#000000""><font color="#666666">Home Loans</font></font></a>  </I></div> </td> </tr></table></body>