Kawasaki ER5/KLE/EX500 - Episode 65 - Camshaft Timing Part 1

[@guruswami9333]

Brilliant set of videos - thanks a bunch :) I had parts of a KLE sat in my shed for 4 years (2 engines one with a damaged head and one with a big end bearing gone)... I had to skip some videos just because it felt like I was cheating and had to keep some of the puzzle to myself lol

[@natewille126]

Matt, I have been rebuilding my E500 based on these videos and I really appreciate you putting these together! I've learned a ton about my bike. Question: I put the first camshaft into place and went to turn the flywheel to line up the timing marks but it only moves a little like it's in gear. Could it be in gear and if so at this point how do I get it back in neutral? Should the camshaft towards the back of the engine say 'EXT'? Also, I pulled the clutch handle at the end of the clutch cover video (I am rebuilding some of this while in the frame). The clutch handle didn't come back very far. Is this a problem? Thanks!!

[@dirtygarageguy]

Could be it be in gear? I don't know could it? 1) did you take the gearbox out?

[@natewille126]

Yes, I had to replace a bent connecting rod. So, I split the casing and pulled everything out. It was spinning fine until I pulled the clutch handle. Just not sure ho it go into gear,; didn't have the gear shifter in place.

[@martinowl]

Ah that explains it. Wish you had done this vid a month ago, it would have saved me hours of grief,lol.

[@dirtygarageguy]

You wish I had done this months ago?! lol So do I! - thanks for the comment dude

[@relph3]

If you were to have refinished the wear on the cam lobes, how would you have re-hardened them?

[@dirtygarageguy]

Even if the cams are spray welded yes they do. The problem is that you have to make sure the steel is very similar. Most repair shops that do this will harden and temper the cams

[@titoine1998]

I've done the timing on my old er5, the chain's lengh is in spec but the EX mark is a little bit (1mm..) Higher than the cylinder head surface, the IN mark too.. Does it matter ? Because i tried to step a tooth on the sprocket, but the mark came way too low..

[@martinowl]

Hi Matt, Brilliant set of videos, really enjoying watching you work on this engine. Have a gpz500 & have recently done the valve timing. I had the same issue in lining up the cams & I notice your cams are no longer inline with the cylinder head. Also when I was replacing the cams my exhaust cam was held off its seat by the cam lobe whereas both your cams are sat nicely flat in their bearing faces. So I am confused as when I have worked to the same setting as you, I have a different result . This not the first time I have had this happen. The engine has not been started since setting the timing but have turned it over by hand with no issues. Cheers, martin.

[@dirtygarageguy]

The same here, the exhaust cam sits up on the rockers due to the valve overlap, as soon as I set the cams in the correct position I rotated the crank backwards about 10deg so it would sit flat.

[@peregrine257]

Matt. I'm in trouble . Did everything you said in this video but timing marks and TDC do not coincide. When piston number 2 is TDC, my C mark is clockwise by 45 deg. When i move the C mark to align with 12 o clock mark, piston number 2 drops by 11 mm. Above follows installation on new crankshaft which "should" be generic....I have carried out timing sequence 3 times and all seems fine until i rotate engine on mag bolt and all stops after the C mark has rotated anticlockwise to 3 o clock...... cheers mate as near to tears here!!!!

[@dirtygarageguy]

1) is the tesnioner installed 2) are you rotating the enigne the correct way?

[@peregrine257]

@@dirtygarageguy no tensioner installed and rotating magneto bolt anticlockwise

[@dirtygarageguy]

the tensioner needs to be installed otherwise you chain is slack and all over the place.....

[@earshootersmed2627]

13:55 different position cams?

[@KOTR2003]

I was trying to install new cams tonight, did this (C mark for top dead center, and E and I in alignment with top of case). If you notice the cam is cocked up in the shot prior, and in the second shot it is flush. It appears he turned the engine a few degrees anti-clockwise to rotate the lobe off the valve. I tried putting the caps on with the lobes touching the valves, but it slipped off and changed the timing.

[@abdelmoamenhussien5585]

hi i need you

[@UgurYenigun]

usta