Kawasaki ER5/KLE/EX500 - Episode 66 - Camshaft Timing Part 2

[@decab8292]

Holy pink elephants Batman! You have already went above and beyond. What a bloke. Thank you just doesn’t really cut it. 😎

[@riskromer9773]

Got a problem with this. While on C position and trying to time it the EX shaft doesn't sit properly, seems the lobe is lifted by the rocker arm so I really can't align it to the IN shaft. Any ideas?

[@dirtygarageguy]

That is how it is - unfortunately. I've been through this with other people before. And yes, I know it does seem correct, but some other bikes are like this. The root of the camtensioner blade stick out further than it should and that's what needs compressing back . Load the cams in where they align with the marks and then (even with the cam slightly sticking out) tighten down the caps. She'll just seat properly

[@riskromer9773]

@@dirtygarageguy thanks so much for replying, mate. I actually did that but, as I mentioned in a comment in the video following this one, resistance builds up and at a given point it feels very hard to turn then releases. I don't hear anything clacking or hitting but there's this muffled quiet hissing. Wondering if it's either a valve or the chain itself which it's tight and not slacking at all.

[@iaespinosah76]

@@dirtygarageguy Thanks, so it means: the #1piston exhaust valves are going to be sligthly opened when the crankshaft is at "C" mark? I have the same issue, intake shaft installed, but exhaust wont seat due to the #1 cyl shaft lobe, hitting the rocker arm. If I invert the shafts, no issue, but that could not be recommended? . In the video, you are tightening the caps, with the shafts not aligned to the head line: Ex and In? so you do not have the issue, thanks for your help, in advance.

[@martinowl]

No, lol, that was my thinking on the bike after having one issue after another.

[@martinowl]

It came so close to getting lobbed into the canal.

[@dirtygarageguy]

Did I say that?

[@kenledger9356]

Basically a good walk through of the ER5 engine top end rebuild, gets a little confusing when you pointing and talking about the exhaust cam when in fact it was the inlet cam.

[@dirtygarageguy]

Do you mean at 12:32? - Because that is the exhaust cam - exhaust to the left of the image, intake on the right side......

[@martinowl]

Those cam cap threads are really fragile, had the same thing happen with exactly the same hole. Also used the same solution as you.

[@dirtygarageguy]

Yeah luckily kawasaki thread all the way down. I think its due to the thread engagement length. Your only grabbing 5-6mm of threads due to the cam guide acting as a spacer. Really, those 4 bolts need to be 5mm longer and then this wouldn't happen. Good to here that someone else has had this issue. Misery loves company lol

[@thomasanderson5331]

mine too horrible

[@beachboardfan9544]

Why are those cam bearing caps so f*ckin beafy?

[@beachboardfan9544]

beefy*

[@dirtygarageguy]

Because.....

[@kenledger9356]

There are a lot of forces going on as the cam rotates, you do NOT want ANY movement of cams except rotational movement.