KZ1000/1100 cam cap torque. error?

Seems like a reputed outfit like Kawasaki Heavy Industries would have issued at-least one service bulletin addressing such a major specification misprint that is found in hundreds (possibly thousands) of Kawasaki Factory Service Manuals. :whistle:

Was there ever a Kawasaki service bulletin that covers this subject? If so, would somebody please post a copy.

I know this is in reference to a KZ1000, 1100. My factory FSM for my Z1 900 (first addition) shows the cam cap bolt torque at 105 in lbs and torqued in the illustrated sequence.

I can't imagine there would be much difference between the two motors for this subject.

FSM:


No problem...

Well I wish I would have seen this before I started tightening down my cap bolts.
 I tightened the rear camshaft to 142 inch pounds based on 12 foot pounds I had no problems. My question is should I unloosen them and retort them down to the correct torque say 85 inch pounds.

 now the front camshaft couldn't get anything tight on that camshaft at all all eight bolts were stripped I don't know how they had it in there and I rode the bike for a couple thousand miles after they supposedly rebuilt it. So now I'm going to play heal coils in but I noticed all the only two of the four holes will allow the Healy coil to go all the way down that's the ones with the dowels the other two holes the Healy coil won't go as far down.

 so what I did is I ordered 6x20 6x25 and 6x30 Cat bolts the correct ones because I tried tightening them one down and it was just too much play left over I would have never tighten down so basically I want to I think I'm going to on torque the rear cam and torque it back to 85 inch pounds finish tapping the other four bolts holes I already did four of them and then install the heili coil and then torque that to 8085 I'm going to keep you guys informed if there's anything that you can tell me I should do please respond and let me know

The correct bolts are 6x43 - I had to drill the upper section of the un-doweled holes to allow the heli-coils to pass through (see recent post in my build thread)

Yeah I wish I knew that early cuz I can't get the coils back out so I'm going to have to go with the smaller bolts plus I didn't have no problems when I pulled it out everything was tight unfortunately the head's installed torque down and everything and I can't get to the inside bolts on the cap but I was able to rethread it from the top all the way down without drilling it I just had to be careful backing it out letting the metal drop down into the bottom and then blowing it out when I was done but I will retort the intake bolts on the cam and see what happens when I'm done it looks pretty good so far I'll keep everybody updated

   We remember seeing some chatter years ago re: the 12 ft. lb. cam cap spec in the manual being a misprint.  Don't know if there was ever a service bulletin from Mama Kaw published to correct that.
   There's a torque table in the back of the Z1 White Manual on Pg. 143 that also indicates 105 in. lb., same as on Pg. 31 for cam cap installation.  Curious if there's a similar torque table in the back of the KZ1K / 1100 manual(s).  If so, what is spec'd there?

Good Ridin'
slmjim & Z1BEBE 

Lately I've been using the 120 inch lb. torque setting for my cam cap bolts, and all have remained tight between installations.

🙂

 

Well I'm going to loosen up mine and retort them to the correct 105 inch pounds not 122 what I have it set at now the other eight that I have to put helicoils in cuz they were struck by the previous person and I'm surprised they didn't come loose and destroy the bike but here is the aftermarket manual this is not a fixing manual from Kawasaki     

I managed to strip 6 out of 8 cam bolts on the exhaust side setting the valve clearance ive helicoiled them with no problems 

6 to 8 ft/lb is where you want to be but i never use a torque wrench on these and just nip them up by hand with a 10mm spanner.
After over 40 years of building these engines you get a feel of how tight is tight enough 

Yes, the calibrated wrist!