Removal
- 1. Remove the camshaft cover (see page 3-6).
- 2. Remove the right hand crank cover. Discard the gasket. Note the positions of the two different bolt lengths. Discard the 3.5 mm bolts.
1. Right hand crank cover
- 3. 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.
1. 'Dot' mark; 2. Marker line
Note:
- In addition to the 'dot' mark alignment, at TDC, the alignment marks on the camshaft sprockets will point inwards at a point level with the joint face.
- The Tiger 800 and Tiger 800XC camshaft sprockets are common to Daytona 675 and Street Triple models, but use different timing marks.
- The timing marks for Tiger 800 and Tiger 800 XC are identified by the number 8 next to the timing mark.
Camshaft to Cylinder Head Alignment Marks
- 4. 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.
- 5. Evenly release the hydraulic tensioner mounting bolts until the plunger spring tension has been released.
- 6. Remove the hydraulic tensioner and discard the O-ring and gasket.
Installation
- 1. Check that number 1 cylinder is still at top dead centre (TDC).
- 2. Ensure that the wedge fitted earlier is still holding the camshaft drive chain tensioner blade in contact with the camshaft drive chain. Check that the camshaft timing marks (identified with a number 8) point inwards and are level with the joint face of the head.
- 3. To set the hydraulic tensioner onto the first tooth of the ratchet (i.e. minimum extension) carry out the following:
Note:
- If installing a new hydraulic tensioner, do not release the plunger before fitting.
- If installing the original hydraulic tensioner, the engine oil must be drained out of the tensioner to enable the plunger to be set onto the first tooth of the ratchet.
- 4. Hold the resister ring ends together and pull out the plunger.
1. Resister ring ends; 2. Plunger
- 5. Remove the spring.
1. Spring
- 6. While holding the resister ring in place, pour out the engine oil into a suitable container.
- 7. Ensure the resister ring is correctly located as shown in the illustration below.
1. Resister ring
- 9. Hold the resister ends together and push the plunger through the resister ring until the groove for the snap ring aligns with the snap ring.
1. Resister ring; 2. Plunger; 3. Groove for snap ring; 4. Snap ring
- 10. When the groove aligns with the snap ring, release the resister ring and move one end of the snap ring into the groove. Slowly release the plunger to ensure that it is held in place.
1. Groove for snap ring; 2. Snap ring
- 11. Fit a new О-ring and gasket to the hydraulic tensioner.
- 12. Fit the tensioner to the cylinder head as noted for removal. Tighten the bolts to 9 Nm.
- 13. Remove the camshaft drive chain tensioner blade wedge, taking care not to move or damage the tensioner blade.
- 14. To release the hydraulic tensioner, rotate the crankshaft 114 of a turn anti-clockwise using the bolt fitted to the end of the crankshaft. Then rotate the crankshaft clockwise until the 'dot' mark on the primary gear aligns with the line at the bottom of the cover.
- 15. Check that there is tension in the camshaft drive chain and the timing marks at the camshaft sprockets are correctly aligned.
Note: After fitting to the engine, the hydraulic) tensioner will be empty of engine oil. After starting the engine, the camshaft drive chain and tensioner blade will be noisy until full pressure is felt at the tensioner plunger. This could take up to 5 seconds.
- 16. Check that the tensioner plunger is correctly located in the middle of the camshaft drive chain tensioner blade when viewed from above.
- 17. Rotate the engine through 4 full revolutions, and reset number 1 cylinder to TDC. Ensure that the 'dot' mark on the primary gear aligns with the line at the bottom of the cover.
1. 'Dot' mark; 2. Marker line
- 18. Check that the camshaft timing marks align as illustrated below.
Camshaft to Cylinder Head Alignment Marks
- 19. Re-check the tensioner plunger location against the camshaft drive chain tensioner blade.
- 20. Refit the camshaft cover (see page 3-7).
- 21. Fit a new gasket to the right hand crank cover.
- 22. Refit the crank cover.
- 23. Install the bolts, using new 35 mm bolts positioned as noted during removal (the 25 mm bolts may be re-used). Tighten the 25 mm fixings to 8 Nm, and the 35 mm fixings to 9 Nm.
1. Right hand crank cover