4.3 -
Cylinder head assemblies: camshafts
1
Bolt
2
Vertical cylinder head inner timing belt cover
3
Seal
4
Bolt
5
Washer
6
Horizontal cylinder head inner timing belt cover
7
Bolt
8
Valve cover
9
O-ring
10
Vertical cylinder head
11
Horizontal cylinder head
12
Stud bolt
13
Stud bolt
14
Nut
15
Key
16
Camshaft-vertical cylinder head
17
Air intake funnel
18
Bolt
19
O-ring
20
Camshaft end cap
21
Bolt
22
Horizontal cylinder head camshaft
23
Copper gasket
24
Bolt
25
Valve cover
 Parts catalogue
CYLINDER HEAD: TIMING SYSTEM
Vertical cylinder head
HORIZONTAL CYLINDER HEAD
INTAKE MANIFOLDS
 Important
Bold reference numbers in this section identify parts not shown in the figures alongside the text, but which can be found in the exploded view diagram.
Removal of the intake manifolds
 
Operation
Section reference
Remove the seat
E 3, Removal of the seat
Remove the side fairings
E 2, Removal of the side fairings
Remove the battery
P 2, Removal of the battery
Remove the starter contactor
P 3, Starter contactor
Remove the fuel tank
L 2, Removal of the fuel tank
Remove the airbox
L 7, Removal of the airbox
Disconnect the throttle cables from the throttle body
F 1, Removal of the throttle twistgrip
Remove the throttle body
L 6, Removal of the throttle body
 Notes
The procedure can also be carried out with the engine installed in the frame. For clarity, the photos show the engine removed from the frame.
 
Unscrew and remove the nuts (14) securing the intake manifolds of the vertical and horizontal cylinder heads from the studs (13).
Remove the manifolds (17).
If necessary, remove the studs (12) and (13) from the cylinder heads.
Refitting the intake manifolds
Apply the recommended threadlocker to the studs (12) and (13), install them in the cylinder heads and tighten them to the specified torque (Sect. C 3, Engine torque settings).
Locate the intake manifolds (17) and secure with the nuts (14).
Tighten the nuts (14) to the specified torque (Sect. C 3, Engine torque settings).
 
Operation
Section reference
Refit the throttle body
L 6, Refitting the throttle body
Reconnect the throttle cables to the throttle body
F 1, Refitting the throttle twistgrip
Refit the airbox
L 7, Refitting the airbox
Refit the fuel tank
L 2, Refitting the fuel tank
Refit the starter contactor
P 3, Starter contactor
Refit the battery
P 2, Refitting the battery
Refit the side fairings
E 2, Refitting the side fairings
Refit the seat
E 3, Refitting the seat
Removal of the inner timing belt covers and camshaft end caps
 
Operation
Section reference
Remove the seat
E 3, Removal of the seat
Remove the side fairings
E 2, Removal of the side fairings
Remove the battery
P 2, Removal of the battery
Remove the starter contactor
P 3, Starter contactor
Remove the fuel tank
L 2, Removal of the fuel tank
Remove the timing belt covers
N 4.2, Removal of the timing belt covers
Remove the camshaft pulleys
N 4.2, Removal of the timing system assembly
 Notes
For clarity, the figures show the cylinder head removed from engine.
 
Remove the retaining screws (18) and (1) and remove the inner timing belt cover (2) from the vertical cylinder head (10).
Repeat the operation for the horizontal cylinder head (11).
 
 Notes
When removing the covers, take care not lose the Woodruff keys (15) located on camshafts (16) and (22).
Unscrew the bolts (21) of the end cap (20) of the camshaft (16).
Remove the camshaft end cap (20) from the cylinder head and recover the O-ring (19).
Removal of the valve covers
 
Operation
Section reference
Remove the seat
E 3, Removal of the seat
Remove the side fairings
E 2, Removal of the side fairings
Remove the battery
P 2, Removal of the battery
Remove the starter contactor
P 3, Starter contactor
Remove the fuel tank
L 2, Removal of the fuel tank
Remove the oil cooler
N 2.2, Removal of the oil cooler
Undo the retaining screws (7) of valve covers (8) and (25) and remove the covers with relative O-rings (9).
 
 
Refitting the valve covers
Always fit new O-rings (9) when refitting the valve covers.
Fix the valve covers (8) and (25) with the relative O-rings (9) to the cylinder head.
Tighten the bolts (7) to the specified torque (Sect. C 3, Engine torque settings).
 
Operation
Section reference
Refit the oil cooler
N 2.2, Refitting the oil cooler
Refit the fuel tank
L 2, Refitting the fuel tank
Refit the starter contactor
P 3, Starter contactor
Refit the battery
P 2, Refitting the battery
Refit the side fairings
E 2, Refitting the side fairings
Refit the seat
E 3, Refitting the seat
Removal of the camshafts
 
Operation
Section reference
Remove the seat
E 3, Removal of the seat
Remove the side fairings
E 2, Removal of the side fairings
Remove the battery
P 2, Removal of the battery
Remove the starter contactor
P 3, Starter contactor
Remove the fuel tank
L 2, Removal of the fuel tank
Remove the timing belt covers
N 4.2, Removal of the timing belt covers
Remove the timing belts and camshaft timing belt pulleys
N 4.2, Removal of the timing system assembly
 Notes
This operation can be carried out with the rocker arms installed in the cylinder head. For clarity, the photos show the cylinder head with the opening rocker arms removed.
 
Remove the camshaft end caps as described above.
Remove the key (15) from the camshaft.
 Notes
To prevent possible damage to components, turn the camshaft (16) through a series of rotations so that the cams do not foul the rockers.
 Notes
If the rocker arms are installed in the cylinder head, remove the spring (A) of the opening rocker arm (B) to facilitate operations.
Withdraw the camshaft (16) from its housing.
Remove the oil seal (3) from the cylinder head.
Inspecting the camshafts
Check the cam contact surfaces for scratches, grooves, steps and waving. Worn cams are frequently the cause of poor timing, which leads to loss of engine power.
Install the camshaft between two centres and check for distortion using a dial gauge:
- service limit: 0.1 mm.
 Notes
The effective distortion will be half the total reading obtained on the dial gauge.
Each camshaft is stamped with an identification letter:
O: horizontal;
V: vertical.
Checking the oil seals
Fit new oil seals at each engine overhaul.
Insert the new oil seals squarely in their bores. Use suitable drifts.
Lubricate the lip of oil seals after assembly. This operation must be performed very carefully.
Refitting the camshafts
If removed, install the oil seal (3) in the bore on the right-hand side of the cylinder head using a suitable drift.
 Important
If the rockers arms are already installed in the cylinder head (Sect. N 4.4, Refitting the rocker arms, shims and valves), insert the camshaft (16), carefully rotating it as you go, so that the camshaft lobes do not foul the rocker arms.
Before fitting the camshaft, check the punch mark: “V” means vertical, “O” means horizontal.
Apply graphite oil to the seats of the camshaft so that it is lubricated also during the initial revs of the engine.
Insert the camshaft (16) from the left-hand side of the cylinder head.
If previously removed, relocate the spring (A) of the opening rocker arm (B).
Check the condition of the Woodruff key (15) and its groove, and install it.
 
Operation
Section reference
Refit the inner timing belt covers and camshaft end caps
N 4.3, Refitting the camshaft end caps
Refit the timing belts and camshaft timing belt pulleys
N 4.2, Refitting the timing system assembly
Refit the timing covers
N 4.2, Refitting the timing belt covers
Refit the fuel tank
L 2, Refitting the fuel tank
Refit the starter contactor
P 3, Starter contactor
Refit the battery
P 2, Refitting the battery
Refit the side fairings
E 2, Refitting the side fairings
Refit the seat
E 3, Refitting the seat
Refitting the camshaft end caps
Lubricate the new O-rings (19) with the recommended grease and fit on the end cap (20).
Fit the end cap (20) on the left-hand side of the cylinder head.
Secure the end cap (20) with the bolts (21).
Tighten the bolts (21) to the specified torque (Sect. C 3, Engine torque settings).
 Notes
Take care not to dislodge the key (15) located on camshaft (16).
Locate the inner timing belt cover (2) of the vertical cylinder head on the left-hand side of the cylinder head and insert the retaining screws (1) and (18).
Tighten the bolts (18) and (1) to the specified torque (Sect. C 3, Engine torque settings).
Repeat the above operations for the other cylinder head (11).
 
Operation
Section reference
Refit the camshaft timing pulleys to the cylinder heads
N 4.2, Refitting the timing system assembly
Refit the timing belt covers
N 4.2, Refitting the timing belt covers
Refit the fuel tank
L 2, Refitting the fuel tank
Refit the starter contactor
P 3, Starter contactor
Refit the battery
P 2, Refitting the battery
Refit the side fairings
E 2, Refitting the side fairings
Refit the seat
E 3, Refitting the seat
1