Valve Spring Compressor Assembly:
57001-241

Valve Seat Cutter Holder Bar:
57001-1128

Valve Spring Compressor Adapter,
57001-1019

Valve Seat Cutter, 32° 57001-1199

33:

25:

25:

Valve Seat Cutter, 45° 57001-1114

27.5:

Valve Seat Cutter, 60° 57001-1328

Valve Seat Cutter, 45° 57001-1115

32:

Valve Seat Cutter Holder,
57001-1330

28:

4.5:

5-10 ENGINE TOP END
Special Tools and Sealant
Valve Guide Arbor,
57001-1331

4.5:

Valve Guide Reamer,
57001-1333

Valve Seat Cutter, 60° 57001-1334

Compression Gauge Adapter, M10 × 1.0:
57001-1601

4.5:

L-Shape Hose:
57001-1606

33:

Washer:
57001-1612

Valve Guide Driver:
57001-1564

Valve Spring Compressor Adapter,
57001-1586

Liquid Gasket, TB1211F:
92104-0004

24:

Liquid Gasket, TB1216B:
92104-1064

ENGINE TOP END 5-11
Clean Air System
Air Suction Valve Removal

the air switching valve (see Air Switching Valve
• Remove
Removal).
the clamps [A].
• Open
Roll
up
• [B]. the front side of the heat insulation rubber plate

(Both Sides):
• Remove
Air Suction Valve Cover Bolts [A]
Air Suction Valve Cover [B]

(Both Sides):
• Remove
Air Suction Valve [A]

Air Suction Valve Installation

the air suctions valve so that opening [A] of the reed
• Install
faces downward.
the air suction valve covers [B].
• Install
Apply
a
non-permanent locking agent to the threads of
• the air suction
valve cover bolts [C], and tighten them.
Torque - Air Suction Valve Cover Bolts: 10 N·m (1.0 kgf·m,
89 in·lb)

• Install the removed parts (see appropriate chapters).

5-12 ENGINE TOP END
Clean Air System
Air Suction Valve Inspection

the air suction valve (see Air Suction Valve Re• Remove
moval).
inspect the reeds [A] for cracks, folds, warps,
• Visually
heat damage or other damage.

•

If there is any doubt as to the condition of the reeds, replace the air suction valve as an assembly.
Check the reed contact areas [B] of the valve holder for
grooves, scratches, any signs of separation from the
holder or heat damage.
If there is any doubt as to the condition of the reed contact
areas, replace the air suction valve as an assembly.
If any carbon or other foreign particles have accumulated
between the reed and the reed contact area, wash the
valve assembly clean with a high flash-point solvent.

NOTICE
Do not scrape off the deposits with a scraper as this
could damage the rubber, requiring replacement of
the suction valve assembly.

Air Switching Valve Removal
NOTICE
Never drop the air switching valve especially on a
hard surface. Such a shock to the air switching
valve can damaged it.
the air cleaner housing (see Air Cleaner Housing
• Remove
Removal in the Fuel System (DFI) chapter).
the connector [A].
• Disconnect
Disconnect
the hoses [B] from the air suction valve cov• ers, and remove
the air switching valve [C].

Air Switching Valve Installation

the air switching valve [A] with hose [B] as shown.
• Install
Front [C]
Left Side View [D]
Yellow Paint [E]

ENGINE TOP END 5-13
Clean Air System
Air Switching Valve Operation Test

to the Air Suction System Damage Inspection in the
• Refer
Periodic Maintenance chapter.

Air Switching Valve Unit Test

to the Air Switching Valve Unit Test in the Electrical
• Refer
System chapter.

Clean Air System Hose Inspection

certain that all the hoses are routed without being flat• Be
tened or kinked, and are connected correctly to the air
cleaner housing, air switching valve and air suction valve
covers.
If they are not, correct them. Replace them if they are
damaged.

5-14 ENGINE TOP END
Cylinder Head Cover
Cylinder Head Cover Removal

• Remove:
Air Switching Valves (see Air Switching Valve Removal)
Throttle Body Assy (see Throttle Body Assy Removal in
the Fuel System (DFI) chapter)
Stick Coils (see Stick Coil Removal in the Electrical System chapter)
the clamps [A].
• Open
Roll
up
• [B]. the front side of the heat insulation rubber plate

• Remove:
Cylinder Head Cover Bolts [A] with Rubber Washers [B]
Cylinder Head Cover [C]

Cylinder Head Cover Installation

the plug hole gaskets with new ones.
• Replace
Be
sure
to
the following parts.
• Dowel Pinsinstall
[A]
Plug Hole Gaskets [B]

ENGINE TOP END 5-15
Cylinder Head Cover
the cylinder head cover gasket [A] with a new
• Replace
one.
a high flash-point solvent, clean off any oil or dirt
• Using
that may be on the liquid gasket coating area. Dry them

•

with a clean cloth.
Apply liquid gasket [B] to the cylinder head as shown.
Sealant - Liquid Gasket, TB1216B: 92104-1064

• Install the new cylinder head cover gasket.
NOTE

○Make the application finish within 20 minutes when the
liquid gasket (TB1216B) to the mating surface of the
cylinder head cover is applied.

the cylinder head cover.
• Install
Replace
rubber washers with new ones.
• Install thetherubber
washers [A] with the metal side faces
• upward.

the cylinder head cover bolts following the speci• Tighten
fied tightening sequence [1  6].
Torque - Cylinder Head Cover Bolts: 10 N·m (1.0 kgf·m, 89
in·lb)

installing the sub covers [A], install them as follows.
• When
• Install:
Collar [B]

•

Sub Covers
Apply a non-permanent locking agent to the threads of
the sub cover bolts [C], and tighten them.
Torque - Sub Cover Bolts: 10 N·m (1.0 kgf·m, 89 in·lb)

• Install the removed parts (see appropriate chapters).

5-16 ENGINE TOP END
Camshaft Chain Tensioner
Camshaft Chain Tensioner Removal
NOTICE
This is a non-return type camshaft chain tensioner.
The push rod does not return to its original position
once it moves out to take up camshaft chain slack.
Observe all the rules listed below.
When removing the tensioner, do not take out the
mounting bolts only halfway. Retightening the
mounting bolts from this position could damage
the tensioner and the camshaft chain. Once the
bolts are loosened, the tensioner must be removed
and reset as described in “Camshaft Chain Tensioner Installation”.
Do not turn over the crankshaft while the tensioner
is removed. This could upset the camshaft chain
timing, and damage the valves.

• Remove:
Upper Fairing Assembly (see Upper Fairing Assembly
Removal in the Frame chapter)
Pad [A]

ZX1000RG/SG
Remove:
Camshaft Chain Tensioner Cap Bolt [A] and O-ring
Camshaft Chain Tensioner Mounting Bolts [B]
Camshaft Chain Tensioner Body [C]
Gasket [D]

•

ENGINE TOP END 5-17
Camshaft Chain Tensioner
ZX1000RH/SH/ZH
Remove:
Cap Bolt [A]
Washer [B]
Spring [C]
Rod [D]
Mounting Bolts [E]
Camshaft Chain Tensioner Body [F] (with O-ring [G])

•

Camshaft Chain Tensioner Installation
ZX1000RG/SG
Turn the push rod mechanism of the chain tensioner body
[A] counterclockwise with a suitable Allen wrench [B].

•

NOTICE
Do not push the push rod strongly while turning
the Allen wrench. The push rod mechanism may
be damaged.
the Allen wrench [A] and attach it again while
• Remove
pushing the push rod if necessary.

the gasket with a new one.
• Replace
Install
the
• Tighten: camshaft chain tensioner body [A].
•
Torque - Camshaft Chain Tensioner Mounting Bolts [B]: 10
N·m (1.0 kgf·m, 89 in·lb)

out the Allen wrench [C].
• Take
Replace
the O-ring with a new one.
• Apply grease
• Tighten: to the O-ring and install it.
•
Torque - Camshaft Chain Tensioner Cap Bolt: 5.0 N·m (0.51
kgf·m, 44 in·lb)

• Install the removed parts (see appropriate chapters).

5-18 ENGINE TOP END
Camshaft Chain Tensioner
ZX1000RH/SH/ZH
Replace the O-ring [A] with a new one.
Apply grease to the new O-ring.
Release the stopper [B] and push the push rod [C] into
the interior of the tensioner body [D].
Install the tensioner body so that the stopper faces upward.
Tighten the tensioner mounting bolts [E].

•
•
•
•
•

Torque - Camshaft Chain Tensioner Mounting Bolts: 9.8
N·m (1.0 kgf·m, 87 in·lb)

• Install:
Rod [F]
•

Spring [G]
Washer [H]
Tighten the cap bolt [I].
Torque - Camshaft Chain Tensioner Cap Bolt: 20 N·m (2.0
kgf·m, 15 ft·lb)

ENGINE TOP END 5-19
Camshaft, Camshaft Chain
Camshaft Removal

• Remove:
Cylinder Head Cover (see Cylinder Head Cover Removal)
Crankshaft Sensor Cover (see Crankshaft Sensor Removal in the Electrical System chapter)
a wrench on the timing rotor bolt [A], turn the crank• Using
shaft clockwise until the line [B] (TDC mark for #1,4 pistons) on the timing rotor [C] is aligned with the mating surface [D] of the crankcase.

the camshaft chain tensioner (see Camshaft
• Remove
Chain Tensioner Removal).
the upper camshaft chain guide bolts and
• Loosen
camshaft cap bolts gradually and evenly as shown se-

•
•

quence [1  20], and remove them.
Remove:
Upper Camshaft Chain Guide [A]
Camshaft Caps [B]
Camshafts [C]
Stuff a clean cloth into the chain tunnel to keep any parts
from dropping into the crankcase.

5-20 ENGINE TOP END
Camshaft, Camshaft Chain

• Remove:
Camshaft Sprocket Bolts [A]
Camshaft Sprockets

NOTICE
The crankshaft may be turned while the camshafts
are removed. Always pull the chain taut while turning the crankshaft. This avoids kinking the chain
on the lower (crankshaft) sprocket. A kinked chain
could damage both the chain and the sprocket.

Camshaft Installation
NOTE

○The exhaust camshaft has a 1001 EX mark [A] and the
intake camshaft has a 3154 IN mark [B]. Be careful not
to mix up these shafts.

the camshaft sprockets as shown.
• Install
#4 Cam Positions [A]
Intake Camshaft Sprocket [B]
Exhaust Camshaft Sprocket [C]
The
○ intake camshaft sprocket and exhaust camshaft
sprocket are identical.
Apply a non-permanent locking agent to the threads of
the camshaft sprocket bolts and tighten them.

•

Torque - Camshaft Sprocket Bolts: 15 N·m (1.5 kgf·m, 11
ft·lb)

molybdenum disulfide oil solution to all cam parts,
• Apply
journals and tappets.
If a new camshaft is to be used, apply a thin coat of molybdenum disulfide grease to the cam surfaces.
a wrench on the timing rotor bolt [A], turn the crank• Using
shaft clockwise until the line [B] (TDC mark for #1,4 pistons) on the timing rotor [C] is aligned with the mating surface [D] of the crankcase.

NOTICE
The crankshaft may be turned while the camshafts
are removed. Always pull the chain taut while turning the crankshaft. This avoids kinking the chain
on the lower (crankshaft) sprocket. A kinked chain
could damage both the chain and the sprocket.

ENGINE TOP END 5-21
Camshaft, Camshaft Chain
the tension side (exhaust side) [A] of the chain taut
• Pull
to install the chain.
the camshaft chain with the sprockets so that tim• Engage
ing marks on the sprockets are positioned as shown.

○The timing marks must be aligned with the cylinder head
upper surface [B].
EX Mark [C]
IN Mark [D]
#1 Pin [E]
#2 Pin [F]
#28 Pin [G]
#29 Pin [H]

• Check that the timing marks [A] are securely aligned.

5-22 ENGINE TOP END
Camshaft, Camshaft Chain
the ten dowel pins on the marks [A].
• Install
Install
camshaft cap, following the identification No.
• [B] andtheupper
camshaft chain guide [C].
First
tighten
the
camshaft cap bolts evenly to seat the
• camshaft in place,allthen
tighten all bolts following the specified tightening sequence [1  20].

Torque - Camshaft Cap Bolts [1  18]: 12 N·m (1.2 kgf·m,
106 in·lb)
Upper Camshaft Chain Guide Bolts [19, 20]: 12
N·m (1.2 kgf·m, 106 in·lb)

the camshaft chain tensioner (see Camshaft Chain
• Install
Tensioner Installation).
the crankshaft 2 turns clockwise to allow the ten• Turn
sioner to expand and recheck the camshaft chain timing.
• Install the removed parts (see appropriate chapters).

Camshaft, Camshaft Cap Wear Inspection

the camshaft caps (see Camshaft Removal).
• Remove
Cut
the
strips
of plastigage (press gauge) to journal width.
• Place a strip on
each journal parallel to the camshaft in-

•

stalled in the correct position.
Tighten the camshaft cap bolts and upper camshaft chain
guide bolts to the specified torque (see Camshaft Installation).

NOTE

○Do not turn the camshaft when the plastigage is between the journal and camshaft cap.
the camshaft cap again, measure each clear• Remove
ance between the camshaft journal and the camshaft cap
using plastigage [A].
Camshaft Journal/Camshaft Cap Clearance
Standard:
0.038  0.081 mm (0.0015  0.0032 in.)
Service Limit: 0.17 mm (0.0067 in.)

ENGINE TOP END 5-23
Camshaft, Camshaft Chain
If any clearance exceeds the service limit, measure the
diameter of each camshaft journal with a micrometer.
Camshaft Journal Diameter
23.940  23.962 mm (0.94252  0.94338
Standard:
in.)
Service Limit: 23.91 mm (0.9413 in.)

If the camshaft journal diameter is less than the service
limit, replace the camshaft with a new one and measure
the clearance again.
If the clearance still remains out of the service limit, replace the cylinder head unit.

Camshaft Runout Inspection

the camshafts (see Camshaft Removal).
• Remove
Set
the
camshaft
in a camshaft alignment jig or on V
• blocks.
the runout with a dial gauge at the specified
• Measure
place as shown.
If the runout exceeds the service limit, replace the
camshaft.
Camshaft Runout
Standard:
TIR 0.02 mm (0.0008 in.) or less
Service Limit: TIR 0.1 mm (0.004 in.)

Cam Wear Inspection

the camshafts (see Camshaft Removal).
• Remove
Measure
[A] of each cam with a micrometer.
• If the camstheareheight
worn down past the service limit, replace
the camshaft.
Cam Height
Standard:
Exhaust

35.043  35.157 mm (1.3796  1.3841 in.)

Intake

38.243  38.357 mm (1.5056  1.5101 in.)

Service Limit:
Exhaust

34.94 mm (1.376 in.)

Intake

38.14 mm (1.502 in.)

Camshaft Chain Removal

• Remove:
Camshafts (see Camshaft Removal)
Timing Rotor (see Timing Rotor Removal in the Electrical
System chapter)
Front and Rear Camshaft Chain Guides (see Cylinder
Head Removal)

5-24 ENGINE TOP END