Kawasaki WORKHORSE 250 (2003) [77/322] Engine top end 4 13

ENGINE TOP END 4-13

Camshaft Sprocket

•

Fit the sprocket under the chain and slip it over the s houl-

der on the camshaft so that the tab on the sprocket fits the

hole in the end of the camshaft and the punch mark [A]

on the sprocket aligns with the pointer [B] on the cylinder

head.

•

Apply molybdenum disulfide oil to the threads of the

camshaft sprocket bolt.

•

Tighten the camshaft sprocket bolt, while holding the

crankshaft from turning with a wrench on the alternator

rotor bolt.

Torque - Camshaft Sprocket Bolt: 34 N·m (3.5 kgf·m, 25

ft·lb)

•

Install the camshaft chain tensioner (see Camshaft Chain

Tensioner Installation).

•

Before going any further, check the cam timing.

○

Turn the crankshaft counterclockwise with a wrench on

the alternator rotor bolt, until the punch mark on the

sprocket realigns with the pointer on the head.

CAUTION

If any resistance is felt when turning the crankshaft,

stop immediately, or you may bend the valves.

○

The “T” mark on the alternator rotor s hould align with the

slot.

If the camshaft timing is not correct, remove the sprocket

from the camshaft, and install it again as detailed above.

•

Smear a little engine oil on the camshaft cover O-ring [A],

and push the cover into place.

•

Put in the camshaft cover bolts and tighten them securely.

•

Install the timing inspection plug.