Reassembly- Cam Timing

Alright, thanks guys. For some reason, I am getting this feeling that I am asking too many questions, so I will try and lighten up with them. I think I have it under control now. I just need to bring my laptop to school tomorrow for this website (blocked at school), and so I can read the manual. Btw, I did download all 185MB of manual, and it did open, too.

lol...it's all good...don't blush,Bud...We all make them.:laugh:
That's what this place is all about.

Erik,You're not asking too much Bud,but DO...spend some time on that manual,and You'll have a way better idea,and then get back in here and let Us know where You're with all of it...We'll get Ya there,but You HAVE to go at an easy,steady pace,because it WILL take some time.

Good work boys.Cuddies your in good hands.They have everything exactly right.

I did a write up some time ago on this and it included pics... not sure where it went to... Here is the text:

Timing the Cams/Valves on a 73-80 Z/KZ

1. First, make sure that your cam chain guide located on top the head,
and your cam chain tensioner, located at the rear of the cylinder are
NOT installed. Also remove all four spark plugs.

2. Using the 17mm bolt head located on the end of your crankshaft
and under the timing cover, turn the engine over clockwise until
the #4 cylinder is at top dead center; that is, the #4 piston, which
is the one closest to you as you face the timing cover, is right at the
top of its stroke and the mark on the case aligns with the TDC timing
mark for the 1&4 cylinders. You can stick a pencil or your finger into
the #4 plug hole and feel the piston crown (top). There is also a 2&3
timing mark opposite that you DO NOT want to use. The following drawing
shows the alignment while the #4 (and #1 piston as well) are at TDC.
The ignition plate is removed for clarity.

img3.photobucket.com/albums/v12/wiredgeorge/KZ900/cam_1.jpg

3. Put your exhaust cam into the head in the lower cam cap holders.
Put the "tick mark" on the cam sprocket facing towards the front mating
edge of the cylinder head.

4. Put your cam caps on and finger tighten the bolts for the exhaust
cam shaft.

5. Noting the cam chain pin adjacent to or slightly above the "tick mark"
on the exhaust cam chainsprocket, counting counter-clockwise, or to your
left, count 28 pins. Mark this pin with an indelible marker.

6. Lift the cam chain and place the intake cam in position where the
"28 arrow mark" is directly UNDER the marked cam chain pin.

7. Put your cam caps on the the intake camshaft and finger tighten
the bolts. This drawing shows the positioning of the marks. Unfortunately,
it has the upper cam chain guide already in place so the 28
pins can not be counted.

img3.photobucket.com/albums/v12/wiredgeorge/KZ900/cam_2.jpg

8. Now you can go ahead and torque the cam shaft bolts. If these bolts
are chromed, torque to 108 inch-lbs. and do not use thread locker or
anti-sieze compound. These bolts are easily stripped so take
care. They should be tightened in a specific order so consult your manual.
The cam caps also are numbered and MUST be reinstalled with the numbers
in the correct location so the cam bearing clearance can be correctly
maintained.

9. Reinstall the upper cam chain guide. Torque the bolts that hold it
to the specs in your manual.

10. Reinstall the cam chain tensioner using a NEW gasket. Torque the
two bolts holding it in place. With the locking bolt loose, turn the
engine over by hand a couple times to ensure that the spring loaded
plunger on the tensioner takes the slack out of the cam chain and
then tighten the lock nut on the lock
bolt on the side.

wiredgeorge Feb. 27, 2004

Wow, great write up, George.


I worked on the bike today. I follwed all steps mentioned, and did take my time. I did everything right (double and triple check each time!), but it seems that I cannot get the chain to be on the crank! I tried 3 times, going through all the steps, and come to the point of turning the motor over, and the chain is not on the crank . Before putting the cams in and doing all the 28 pin stuff, I am making sure (well obviously not) that chain is on. I hold it as tight as possible with my hand while slowly turning the motor over, and while holding the chain tight, it doenst slip; but once I get the whole thing over and the cams in place, it slips.

I will just have to go back until I get this right.

It's ok, I still have time- I'm waiting on a petcock since the old one is toast, and waiting to have the gas tank flushed.

Cuddies....you are doing fine. All the guys on here are correct as usual and you will get it soon enough. I just did all the same things this past weekend (May 19th) and it took me a while to get mine right even though I had done it before. Once you get the cam chain on the crankshaft, and you are sure its there, dont let off the tension. Slide your intake cam in place while keeping tension on the cam chain. Do the same with the exhaust cam and then you shouldnt have to worry about the chain falling off the crankshaft. Once both cams are in, you can adjust them to the correct marks on the gears....Keep us posted and if you need any more help....keep asking away. All these old KZ heads love to help get another one back on the road....

Later, OldSkool73(74)

Post edited by: OldSkool73, at: 2007/05/23 12:51

Post edited by: OldSkool73, at: 2007/05/23 12:54

Well, got it completely together today . Turned the motor over about 20 times jsut to make COMPLETE sure nothing was going wrong. Ok, Ok, I was just playing :whistle:


I am now just waiting for this insane expessive gas tank/petcock stuff to work itself out. I took the tank down to get flushed, but they told me there was a 99% chance that the tank paint would be ruined. Now trying to keep this bike as orignal as possible, I took the tank home with me and am going to try my own way, or I should say I am going to try the way that is on here.

What is your guy's suggestions to my petcock problem.. Should I just drop the $80 insane dollars for a new one, or should I rebuild this one I have now? BTW, I tried just looking for a rebuild kit, but can't even find one...I mean, I see the 'vacuum' and all that stuff, but I don't know which kit is for me.

Any progress/updates??:whistle:

Hey guys, this is the same guy. I couldn't remember the password for cuddies so i shortened it up and am using cuds now.



I'm sure you have all seen my threads. Progress started again.