Camshaft Removal
SAFETY FIRST: Protective gloves and eyewear are recommended at this point.
Note: The 1992 - 1997 Katana 600 models have tappet shims to adjust the valve clearance unlike the other models that have screw and locknut type adjustment.
Note: The 1996 - 1997 Katana 600 models have a different style cam chain with a cam chain guide instead of an idler gear.
Remove the cylinder head cover. See the Cylinder Head Cover topic for more information.
Remove the generator. See the Generator topic for more information.
Loosen the five signal generator cover bolts with a 5 mm Allen. Remove the bolts. The forward most bolt has a sealing a sealing washer.
The 1988 - 1995 models have a different looking signal generator rotor from the 1996 and newer models shown below.
Remove the generator cover and gasket.
The valve clearance should be checked when the cam lobe for the valve being checked either faces up or to the side away from the rocker arm. Do not inspect the valve clearance when the lobe is against the rocker arm.
The notches on the camshafts should be level with the cylinder head cover mating surface and facing out. If necessary, Turn the crankshaft over one full turn to move the notches 180°.
Loosen the cam chain tensioner cap bolt with a 19 mm socket. Remove the cap bolt, sealing washer, and spring from the cam chain tensioner.
Loosen the cam chain tensioner mounting bolts evenly with a 5 mm Allen. Remove the cam chain tensioner mounting bolts.
Remove the cam chain tensioner and gasket.
Inspect the cam chain tensioner. Press in the ratchet and make sure the tensioner rod will push back in the body and the ratchet mechanism works correctly. Replace the cam chain tensioner as needed.
Remove the four cam chain idler bolts with a 10 mm socket.
Remove the cam chain idler.
Remove the cam chain guide bolts with a 10 mm socket on the 1996 - 1997 Katana 600 models. Remove the cam chain guide.
The camshafts are held in the cylinder head by five holders and the cam chain.
Note the markings and original location on the camshaft holders.
Remove the camshaft holder bolts evenly with a 10 mm socket.
Remove the camshaft holders and dowel pins.
Lift up on the cam chain and remove the camshafts.
Do not allow the cam chain to slip into the crankcase. Secure the cam chain with a piece of wire.
The camshafts are marked for intake and exhaust.
Use plastigauge to check the clearance between camshafts and the holder journals. Place the plastigauge over the camshaft where the holder fits. Install the holder to its original position and torque the bolts to specification with a 10 mm socket. Remove the camshaft holders and check the plastigauge according to its clearance chart. Measure at the widest section of the plastigauge for an accurate measurement.
(Camshaft Holder Bolt Torque: 10 N-m or 7.0 lb-ft)
| Item | Standard mm (in) | Limit | |
| Camshaft journal oil clearance | IN. and EX. | 0.032-0.066 (0.0013-0.0026) |
0.150 (0.0059) |
Special Tools- Plastigauge 09900-22301 or 09900-22302
If the journal clearance is out of specification measure the outside diameter of the camshaft journal with a micrometer. Also, measure the inside diameter of the holder. Replace the camshaft or cylinder head as needed.
| Item | Standard mm (in) | |
| Camshaft journal holder I.D. | IN. and EX. | 22.012-22.025 (0.8666-0.8671) |
| Camshaft journal O.D. | IN. and EX. | 21.959-21.980 (0.8645-0.8654) |
To separate the sprocket from the camshaft remove the bolts with a 10 mm socket.
Inspect the camshaft for wear and damage. If the camshaft lobe is damaged also inspect the rocker arm. Measure the camshaft lobe height with a micrometer.
| ITEM | SPECIFICATION mm (in) | LIMIT | |
| Cam height
600 1988 - 1991 |
IN. | 33.617-33.657 (1.3235-1.3251) |
33.320 (1.3118) |
| EX. | 32.882-32.922 (1.2946-1.2961) |
32.590 (1.2831) |
|
| Cam height
600 1992 - 1993 US 49-State 1994 - 1997 |
IN. | 33.632-33.688 (1.3241-1.3263) |
33.330 (1.3122) |
| EX. | 32.902-32.958 (1.2954-1.2976) |
32.600 (1.2835) |
|
| Cam height
600 California 1994 - 1997 |
IN. | 33.442-33.498 (1.2772-1.2794) |
32.150 (1.2657) |
| EX. | 32.182-32.238 (1.2670-1.2692) |
31.980 (1.2555) |
|
| Cam height
750 1989 - 1995 |
IN. | 32.66-32.71 (1.2858-1.2878) |
33.300 (1.3110) |
| EX. | 32.882-32.922 (1.2946-1.2961) |
32.590 (1.2831) |
|
| Cam height
750 1996 - 1997 |
IN. | 33.600-33.644 (1.3228-1.3246) |
33.300 (1.3110) |
| EX. | 32.890-32.934 (1.2949-1.2966) |
32.590 (1.2831) |
|
Remove the cam chain guide.
Inspect the cam chain guide for wear and damage.
To install the camshaft see the Camshaft Installation topic.
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