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simmr · July 28th, 2012, 11:04 AM

I finally had some time:

The loud knocking sound was indeed the valve clearance. However, I'm in a bit more of a jam. The reason they were loose was because the intake camshaft melted, and unfortunately, so did the seats they sit in...

I did not know there was a difference between camshafts, but when I aligned timing to the 2T mark, I noticed (now) that the cam lobes did not match the image in the valve adjustment procedure. At 2t, instead of pointing up, they were pointing down. When I rebuilt the engine, I switched the exhaust and intake camshafts. Oddly enough, it still ran smooth at first...

Some pics I took:
http://imgur.com/a/jjICu

What I don't get is what could have caused this? Problems with oil passages? The fact that I switched the camshafts?

How do I fix this? Looks like I'll have to get a new top end?

Thanks for your help guys.

July 28th, 2012, 11:04 AM	#9
simmr ninjette.org newbie Name: Sergio Location: Ottawa Join Date: Jul 2012 Motorcycle(s): 2003 Kawasaki 250ZZR (Ninja) Posts: 7	Melted Camshaft I finally had some time: The loud knocking sound was indeed the valve clearance. However, I'm in a bit more of a jam. The reason they were loose was because the intake camshaft melted, and unfortunately, so did the seats they sit in... I did not know there was a difference between camshafts, but when I aligned timing to the 2T mark, I noticed (now) that the cam lobes did not match the image in the valve adjustment procedure. At 2t, instead of pointing up, they were pointing down. When I rebuilt the engine, I switched the exhaust and intake camshafts. Oddly enough, it still ran smooth at first... Some pics I took: http://imgur.com/a/jjICu What I don't get is what could have caused this? Problems with oil passages? The fact that I switched the camshafts? How do I fix this? Looks like I'll have to get a new top end? Thanks for your help guys.