Remove the engine guard.
Drain the oil. (when engine is warm)
Remove the seat, the tank fairing, the fuel pipes and the fuel tank.
Remove the exhaust pipes and the spark plug.
Remove the top engine bracket.
Remove the 2 cylinder head covers.
Now you have to put your engine at the right timing. This has to be the TDC ( Top Dead Centre) from the compression stroke. Through the little window on your left crankcasecover you can see the timemarks on the flywheel. You have to put your engine on the ‘A’ mark and make sure it is in the compression stroke. In the compression stroke the valves don’t move, around the ‘A’ mark timingpoint.
Remove the screws from the cylinder head, including the 2 screws underneath the cylinderheadcovers. You can remove the cylinder head and get to the camchain with the sprocket.
Loosen the rear brake pedal, so you be able to remove the right crankcasecover.
Remove the oilfilter, at the end we need to install a new oil filter with new oil.
Loosen the screws on the right crankcasecover and remove the cover.
Now it is time to remove the bolt from the crankshaft, this bolt has a left-handed thread.
To loosen this bolt you need to block the sprocket on the crankshaft. You can block it by putting a 5-eurocent coin between the teeth of the crankshaftsprocket and the clutchsprocket.
The clutch and the clutchhousing need to be removed, otherwise you can’t remove the camchainsprocket from the crankshaft. Remove the screws and the springs, now you remove the pressure plate and the discs.
Remove the thrust bearing
Remove the secured bolt. Now you can remove the clutchhousing.
Remove the camchaintensioner, first loosen the large centre bolt and later the smaller bolts. When you remove the tensioner you can see how many teeth the tensioner is out.
Check the timing of the engine, make sure the crankshaft is still on the ‘A’ mark (the TDC of the compression stroke) The Sprockets on the crankshaft are positioned with a cotter so you can’t install the sprockets in a wrong way on the crankshaft. But now you have to mark het timing on the camshaft to make sure your timing does not change compared with crankshaft. The cams have to point down.
Remove the 2 bolts from the camchainsprocket, they are secured.
Remove the sprocket from the notch on the camchain. The sprocket can now move down. The chain is free now and you can remove the cotter from the crankshaftsprocket and remove the sprocket from the crankshaft.
Remove the camchaintensioner, first loosen the large centre bolt and later the smaller bolts. When you remove the tensioner you can see how many teeth the tensioner is out.
Check the timing of the engine, make sure the crankshaft is still on the ‘A’ mark (the TDC of the compression stroke) The Sprockets on the crankshaft are positioned with a cotter so you can’t install the sprockets in a wrong way on the crankshaft. But now you have to mark het timing on the camshaft to make sure your timing does not change compared with crankshaft. The cams have to point down.
Remove the 2 bolts from the camchainsprocket, they are secured.
Remove the sprocket from the notch on the camchain. The sprocket can now move down. The chain is free now and you can remove the cotter from the crankshaftsprocket and remove the sprocket from the crankshaft.
Now you can take out the camchain and remove the camchainsprocket and the chain.   Install the new sprocket on the crankshaft and put the new chain on it. Put the camshaft back in with the camchainsprocket free on it, put the chain on the sprocket. Put the sprocket on the notch from the camshaft and make sure the marks are on the right place. Check the timing!!! Tighten the bolts back in and secure them. Check the crankshaft timing (A-mark on flywheel) and make sure the camshaft timing corresponds with it. Let the engine make some rotations by hand and check the timing again.   When everything is ok, you can put the other crankshaftsprocket back on and put the clutch back in. With help of the 5-eurocent coin you can tighten the bolt back.  You can put back the cylinder head, but First clean the surfaces. I used the gasket maker ‘Dirko from Elring’   Install the right crankcasecover and the camchaintensioner. Use new gaskets.  Check the valve clearance and adjust it. (clearance between 0.05 and 0.10) Clean the sieve above the oil drain bolt. Install a new oilfilter and put new oil on your bike.  Install the cylinder head covers, the top engine bracket, brake pedal, exhaust pipes and all the other components on your bike. Let your engine rotate by hand first, to check on strange enginenoises. Ready to start the engine. | |
