Question about 1991 kawasaki ZZR 400

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Cam timing camsaft timing and torqe values for top.

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You work on the bike, spend the money on a book.

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SOURCE: timing camsaft

The camshaft caps get 7.2 ft lbs. Tighten them in a cris-cross pattern from inside to outside. Tighten each to 4lbs then 6lbs then final 7.2lbs.

The camshafts should be installed onto the cylinder head so that the punch mark on the exhaust camshaft gear and the punch mark on the intake camshaft gear align with the cylinder head surface.

Set the chain gears in time then check by turning the
crankshaft counterclockwise several turns to rotor T.D.C. mark. Camshaft match marks must align with the cylinder head surface. Out of alignment → Adjust.

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Posted on Apr 05, 2009

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I have a 2002 pt cruiser with a 2.4 litre motor. I've tried to install the timing belt but it does not line up with the 4 scrib marks. I do not know how to rotate the cams in the right order for the belt...

It is typical to have to stretch the belt a tad as you install--needs to be tight across the cam sprockets and from the right cam to the crank gear. Then the tensioner should take up the slack on the other side. 0996b43f80209592.jpg
  1. enlarge_icon.gifenlarge_tooltip.gif
  2. Fig. Camshaft and crankshaft alignment marks-2.4L engine

To install:

0996b43f8020873a.jpg enlarge_icon.gifenlarge_tooltip.gif Fig. Install the belt tensioner

0996b43f8020873b.jpg enlarge_icon.gifenlarge_tooltip.gif Fig. Proper timing belt routing

  1. Set the crankshaft sprocket at TDC by aligning the sprocket with the arrow on the oil pump housing.
  2. Set the camshafts timing marks so that the exhaust camshaft sprocket is a 1 / 2 notch below the intake camshaft sprocket.
  3. Install the timing belt by starting at the crankshaft. Go around the water pump sprocket, idler pulley, camshaft sprockets and the tensioner.
  4. Move the exhaust camshaft sprocket counterclockwise to align the marks and to remove any slack.
  5. Insert a 6mm Allen wrench into the tensioner opening on the top plate of the tensioner pulley. Rotate the top plate counterclockwise. The pulley will move against the belt and the tensioner setting notch will start to move clockwise. Continue to move the top plate counterclockwise until the setting notch is aligned with the spring tang. Using the Allen wrench, to prevent the top plate from moving, tighten the tensioner lock bolt to 220 inch lbs. (25 Nm). Make sure the setting notch and spring tang are still aligned after the lock nut is tighten. If not repeat the procedure.
  6. Remove the wrench from the belt tensioner.
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  7. Rotate the crankshaft two full revolutions and verify that the TDC marks are properly aligned.
  8. Check the spring tang is within the tolerance window, if not repeat the previous two steps.

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