Warning!
- Make sure the motorcycle is stabilised and adequately supported.
- A correctly supported motorcycle will help prevent it from falling.
- An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle.
Perform the following operations:
1. Release the seven fixings and remove the right hand crankcase cover. Discard the gasket.
1. Fixings
2. Rotate the crankshaft clockwise (the normal direction of rotation), using the bolt fitted to the end of the crankshaft. Stop rotation when number 1 cylinder is at Top Dead Centre (TDC), that is when the dot mark on the primary gear aligns with the line on the crankcase.
Note: While rotating the crankshaft, ensure that the front camshaft drive chain rubbing blade remains in its mounting. Before inserting the timing pin, ensure the dot on the primary gear is aligned with the line on the crankcase.
3. Insert T3880601 - Camshaft Timing Pin into the timing holes in the crankcase and crankshaft.
1. DOT alignment mark; 2. Marker line; 3. T3880601 - Camshaft Timing Pin; 4. Timing hole in crankcase
4. In addition to the dot mark alignment, at TDC, the alignment marks on the camshaft bosses will point inwards.
1. Camshaft alignment marks
5. Place a suitable wedge between the camshaft drive chain tensioner blade and crankcase, to hold the camshaft drive chain taut during removal of the tensioner.
Warning! The hydraulic tensioner is under spring tension. Always wear hand, eye, and face protection when withdrawing the tensioner mounting bolts and take great care to minimise the risk of injury and loss of components.
Note: Note the orientation of the hydraulic tensioner.
6. Evenly release the hydraulic tensioner mounting bolts until the plunger spring tension has been released.
7. Remove the hydraulic tensioner and discard the O-ring and gasket.
Camshaft drive chain tensioner - inspection
1. Inspect the camshaft drive chain tensioner spring for damage and deformation. Renew as necessary.
2. Inspect the tip of the camshaft drive chain tensioner plunger for wear and damage. Renew as necessary.