Cam Install

Added by TRX650GFA

This was installed on 2004 Rincon

First remove the tank cover and fuel tank, don't forget to disconnect the fuel gauge wire.

First step, remove the valve covers and spark plug, turn engine over with the recoil to set engine @ TDC on compression. To confirm this, stick something down the cylinder to be sure piston is at the top and then confirm both intake and exhaust rockers are loose.

Next remove the timing chain tensioner.

Then remove the seven 8mm head bolts. Note the location of the four brass washers!

Remove the top motor mount. Now remove the four cap nuts and washers.

Lift off cylinder head cover.

Next loosen clamp for carb at the cylinder head and slide carb assembly back, remove the two 12mm nuts for the exhaust. You will need to loosen the clamp for the muffler so you can slide the head pipe forward. Try to loosen these bolts before ordering your gaskets and stuff to be sure it will come loose or you will be mad. Alot of time these seize and the bolts can break.

Note the location of the push rods so they go back to the same location.

Remove the cylinder head.

Remove the four cam mounting bolts. Remove cam assembly with aluminum tray. Don't let the chain fall!!!!

Next part you should note the assembly of the decompressor or the best thing is to take a picture for reference later.

Next you will need to remove the gear from the old cam to remove the decompressor. This can be a real bitch, heat the gear with a torch. You will not be using this gear so if you bend it or you are worried about the heat - Don't worry.

Now install the decompressor and the gear on the new cam. NOTE: Make sure the gear and cam are clean of oil. Apply loctite green or red to the cam before pressing the gear on.

New cam assembled

Now you will have to grind or cut the aluminum tray to fit the new camshaft.

Confirm that you have enough clearance between the tray and the cam by assembling the two and try turning the camshaft. NOTE: Make sure you have the two dowel pins in the bearing housings.

Once you have confirmed this, install the cam assembly and confirm the timing marks.

Tighten the four mounting bolts. Install the chain tensioner and confirm the timing marks again. Apply lots of clean engine oil over the cam.

Install new head gasket and cylinder head.

Install exhaust head pipe and carb boot on cylinder head.

Replace the push rods back to thier original location, install new cylinder cover gasket and install cover. Apply engine oil to nuts and tighten cap nuts to 41 ft-lbs.

Install the seven 8 mm head bolts, set the valves.

Install top motor mount, fuel tank and plastic.

Change engine oil and filter. Fill back up with antifreeze, check for leaks. Let it warm up and then drive it like you stole it !!!!!!!

Have fun