Camshaft cap question.

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MRLZXR400
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Camshaft cap question.

Post by MRLZXR400 » Fri Jan 25, 2019 1:53 pm

Had the classic simple job turns nasty today.
Whilst re-fitting the cylinder head cover on my L9 after replacing a leaky gasket I sheared a cylinder head cover bolt that screws into the camshaft cap.

I must have overtightened it, I couldn't get a torque wrench in and thought a good nip up would do it and then I got that horrible feeling of a bolt shearing off.🤢

Obviously I now need to get the camshaft cap out and try and drill out the bolt remains.

So my question is, is it possible to remove a camshaft cap without having to re-time the engine etc. or will removing the camshaft cap leave me with a loose camshaft as that would be beyond my skill level etc?

It is camshaft cap 1, front left.

I notice that caps 1&2 appear to be connected, in thinking with an oil way maybe.

I just wondered can I get away with removing cap 1 and re-fitting it without disturbing the whole top end?

Really appreciate any help.

Mark
ZXR400 L9, 2008 Triumph Street Triple, 1960 Triumph Tiger Cub, 1976 Honda TL125, 1996 Ducati 748.

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banner001
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Re: Camshaft cap question.

Post by banner001 » Fri Jan 25, 2019 1:57 pm

The caps are all connected. The bolt will be sheared off in the cylinder head, so you need to remove that which means removing the cams, as long as you set the engine to TDC on 1 or 4 piston you can just realign the cams and the chain...however you should check the timing afterwards for sure. You should also use this opportunity to check the valve clearances, cylinder bores, cam chain and chain tensioner blades.
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Re: Camshaft cap question.

Post by MRLZXR400 » Fri Jan 25, 2019 2:12 pm

Banner, thanks for the quick reply.

Think my description was misleading.

It's the bolt that secures the cylinder head cover.
It actually screws in to the camshaft cap itself rather than in to the cylinder head. Pic below.

I was hoping I could remove the camshaft cap in question leaving the others undesturbed.

What do you think, is that possible or will I have to remove both?
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ZXR400 L9, 2008 Triumph Street Triple, 1960 Triumph Tiger Cub, 1976 Honda TL125, 1996 Ducati 748.

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Re: Camshaft cap question.

Post by MRLZXR400 » Fri Jan 25, 2019 3:52 pm

Sorry Banner, I must've sounded a bit thick in my last post.I've looked at other info about camshaft removal on here and realise they are connected etc., seems quite a job I've created for a weeping gasket!!

I have to confess in my haste I loosened the bolts on the camshaft cap in question, only now have I read how crucial loosening and re-tightening in sequence is on them, do you think I will have done any damage?

What's your advice?

This has not been a good day! 😞
ZXR400 L9, 2008 Triumph Street Triple, 1960 Triumph Tiger Cub, 1976 Honda TL125, 1996 Ducati 748.

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Re: Camshaft cap question.

Post by banner001 » Sat Jan 26, 2019 11:08 am

As long as the camshafts didn't rise upwards, and as long as you didn't take out every single bolt before screwing them back down then they will be fine.

From memory the cam caps are a push fit together, so a quick yank should separate the bad one but you need to do this with all of them off of the engine. Take it to a local engineering shop and see if they can get a left hand drill bit in there, that's usually all it takes. Failing that it's drill and helicoil back to standard size.

Obviously to do this you are going to have to remove all of the cam caps bolts, so I would still take the opportunity to check all of the bits I mentioned before, plus cam wear, lobe damage etc...

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Re: Camshaft cap question.

Post by MRLZXR400 » Sat Jan 26, 2019 7:37 pm

Thanks for the reply again Banner.
No I only loosened the four bolts on the #1 cap (front left) I didn't notice any lift and didn't try to move it and as it is furthest from the camchain I'm assuming the cap next to it that is nearest the chain would've prevented any movement.

Yep, I'm an ex toolmaker (many years ago) so removing the broken stud is within my abilities, mind you I did snap it!!

I was just really concerned I'd caused damage or was going to cause more.

I had that horrible feeling in my stomach when you feel out of your depth.

Thanks again though, your guidance and reassurance is a great help.

I'm thinking of subbing the job out to a local bike guy.

Incidentally where are you based and do you do jobs like this for a fee by any chance?

Mark
ZXR400 L9, 2008 Triumph Street Triple, 1960 Triumph Tiger Cub, 1976 Honda TL125, 1996 Ducati 748.

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Re: Camshaft cap question.

Post by banner001 » Sat Jan 26, 2019 10:19 pm

I'm in Nuneaton in the Midlands, if you can get the bike here we can remove the cam cap covers, check over the engine top end, cam chains, shims etc.

I've got no machining equipment here so couldn't remove the broken bolt for you.

All I can say though is that you do need to remove the entire cam cap cover assembly and then remove the one damaged one. Just remember to block up all the oil passageways, and cover up the mating surfaces and the surfaces that interface with the cam shaft
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Re: Camshaft cap question.

Post by MRLZXR400 » Sun Jan 27, 2019 9:49 am

What a relief!!!
Had a bit of a brain wave and thought maybe if I screw the remains of the bolt back in it might catch on the broken stud and bring it back out with it and bugger me it worked!!
It was a bit like diffusing a bomb but what a relief.
Thanks again though for your support Banner, helped me keep a cool head!
Pic of the offending bolt attached.
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Re: Camshaft cap question.

Post by banner001 » Sun Jan 27, 2019 12:13 pm

:excited
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