Removal
- 1. Remove the rider's seat (see page 16-13).
- 2. Disconnect the battery, negative (black) lead first.
- 3. Remove the fuel tank (see page 10-91).
- 4. Remove the airbox (see page 10-98).
- 5. Remove the ignition coils from the camshaft cover.
1. Ignition coils
- 6. Remove the throttle bodies, injectors and fuel rail from the cylinder head (see page 10-107).
Note: It is not necessary to disconnect the throttle cables. Instead, lay the assembly over the frame during the period when the engine is separated from the frame.
- 7. Progressively release the camshaft cover bolts in the sequence shown below.
Note: Two shorter bolts are fitted at the end adjacent to the camshaft drive chain.
Camshaft Cover Bolt Release Sequence
- 8. Remove the camshaft cover from the motorcycle.
Caution: Never use a lever to remove the camshaft cover from the head. Using a lever will cause damage to the head and camshaft cover which could lead to an oil leak.
- 9. Remove the camshaft cover gasket. If necessary, recover the three dowels from the camshaft ladder (these may come away in the camshaft cover or gasket).
- 10. Discard the camshaft cover gasket and bolt seals.
- 11. Remove any residual oil from the front of the head using a syringe or lint free cloth.
Installation
- 1. Refit the three dowels to the camshaft ladder.
1. Dowels
- 2. Fit a new camshaft cover seal to the cylinder head. Ensure the groove in the gasket is correctly seated to the head. Ensure the plug tower seals and the dowels are correctly located.
1. Camshaft cover seal; 2. Dowels; 3. Plug tower seals
- 3. Fit the camshaft cover, ensuring that the gasket remains in the correct position.
- 4. Lubricate the new camshaft cover screw seals with clean engine oil. Fit the camshaft cover screws and screw seals and tighten until finger tight.
- 5. Finally, tighten the camshaft cover screws, in the same order as for removal, to 10 Nm.
- 6. Refit the throttle bodies, injectors and fuel rail to the cylinder head (see page 10-101).
- 7. Check the throttle cable adjustment (see page 10-104).
- 8. Inspect the ignition coils seal for damage and replace if necessary.
- 9. Fit the ignition coils and reconnect the electrical connectors.
1. Coils