Piston Hole Kz1000LTD 1982

Too late Rolf. One of the bolts is already stripped; I did exactly what you say; clean all threads with brake cleaner, and 3 of them show some metal already; one of them completely stripped. 

So helicoil time for me. 

Good tip about the 1/2 turn each, even if it takes forever. 

Zed,

I was following the manual, in which they say to get the tensioner on right after setting the camshafts.

So basically just set the camshafts, and then close, and then get the tensioner, right?

An interesting thing happened right before I stripped one of the threads. Everything was perfectly aligned, however, the count was not 44 bolts from one arrow to the other. 

Will see after I take care of the threads

Thank you!

Is it the bolt threads or the cam threads? Never stripped a cam thread but broke a few bolts. 
Steve

cartal wrote:

Zed,

I was following the manual, in which they say to get the tensioner on right after setting the camshafts.

So basically just set the camshafts, and then close, and then get the tensioner, right?

An interesting thing happened right before I stripped one of the threads. Everything was perfectly aligned, however, the count was not 44 bolts from one arrow to the other. 

Will see after I take care of the threads

Thank you!

Always something...if not one thing, then it's another.  Just ask SWest

Gotta love it, because if one is not a patient man, then that one will surely go crazy...  

cartal wrote:

Zed,

I was following the manual, in which they say to get the tensioner on right after setting the camshafts.

So basically just set the camshafts, and then close, and then get the tensioner, right?

An interesting thing happened right before I stripped one of the threads. Everything was perfectly aligned, however, the count was not 44 bolts from one arrow to the other. 



Thank you!

YES! The tensioner goes on after the cam cover with these J type engines with hyvo chain otherwise the chain will be too tight and cause damage.
It is only the early engines with top idler that can have the tensioner fitted before the cover .
Also you must have the correct 44 pin count between the camshaft timing mark arrows.
Done correctly the exhaust cam mark will line up with the head at TDC but the inlet won't until the cam cover is fitted .
You don't line up the inlet arrow with the head and just fit the chain without counting the pins otherwise the inlet timing will be wrong and too far advanced.
With the correct 44 pin count and both arrows aligned with the head the section of chain in between the sprockets will not be tight but will sag.
It is the slipper guide in the cover that pushes down on the chain to take up the slack between the sprockets and cause the inlet cam to rotate to the correct position.
You should only fit the tensioner after this is done.
 

Probably my poor english playing havoc again. Stripped the threads of the bolts holding the camshaft "carriers".

So far:

- 1 completely stripped
- 2 running "soft"

Will make sure all are checked, and repaired. I can see a lot of helicoil practice in my near future.

How do the threads look in the cams?

Sorry. I don’t understand the question. 

it’s these bolts’ thread that has been damaged:

 

Hi Carlos, a bit late I know but I have suggested a method for cam removal and install on page 2 of the below thread that should avoid thread damage (or at least in your case "any more thread damage")

Specs/Info on RC424 Cams (Russ Collins) - Page 2 - KZRider Forum - KZRider, KZ, Z1 & Z Motorcycle Enthusiast's Forum

cartal wrote:

Sorry. I don’t understand the question. 

it’s these bolts’ thread that has been damaged:

 

I see, in that case I use helicoils to repair those threads. Sure you can use other methods but if done right they will last a long time at a lower cost and effort. I munged up a bolt hole then had to use a 8x6mm insert to fix it. Still running strong today. 

Steve
I don't edit my videos to show just the successes like others do I show my mistakes and how I overcome them. Sometimes it's a wild and woolly ride. 

rumble.com/v26mqro-installing-the-insert.html
rumble.com/v26n196-finished-the-insert.html


 

I ended up doing 5 threads yesterday. All helicoils went in perfectly; no issues.

i had been thinking all week on how to get the drill 100% straight, and ended using a small bracket out of a vfr750 engine I had had lying around for years. My Diogenes syndrome, and keeping all kind of useless stuff in boxes, paid back this time. 

with the new threads done, I will attempt cam assembly again this evening. 

some pics for reference

 

The old Bessey clamps have saved many threads




They hold both caps down securely, before I remove and/or install the bolts.