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Assembling the Cam Area

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Written by Randy Fox   
Saturday, 03 November 2007

Installing the Cams

Image

 

Next, use a marker pen to mark the cams as follows:

  • Locate the alignment dimple on each cam. Then mark the tooth or gap on the reverse side of the gear, associated with the dimple. See photo above.
  • Locate the alignment dimple on the rear cam. Then mark the first shaft-shoulder, as shown in the photo below.
  • Locate the alignment dimple on the rear cam again. Then mark the shaft-shoulder near the threads. See photo below.

Cams, Yamaha Road Star

 

These marks on the rear cam, together with the circle-hole in the end of the front cam, enabled me to easily verify that the cams remained aligned even after the camshaft cover was installed (and covered the gear alignment dimples).

Insert two camshaft case alignment dowels into the engine case. These are the little solid dowels. Then put on a new camshaft cover gasket.

Apply a film of assembly lube on the following:

  • The bearing surfaces of both cams
  • Both cam bearings of the camshaft cover
  • Both cam bearings in the engine case

 

Now, insert the cams into the camshaft cover (not the engine case), aligning the dots on the cam gears.

Tip: don't worry that you can't easily rotate the cams together yet. The rear cam employs a spring-loaded split-gear to maintain zero lash. This makes rotation by hand difficult.

Take picts.

Liberally coat the lobe surfaces of both cams with assembly lube.

Now, install the camshaft cover (with cams mounted) into the engine case.

Tip: Be careful that the front cam does not come loose from the cover as you install it. I know that the service manual recommends installing the front cam retaining washer to prevent this, but it isn’t difficult. And with the washer off, you can verify cam alignment afterwards.

If you feel uneasy about this, feel free to put on the front cam retaining washer to hold the cams in place. Then take it back off after cam cover installation.

 

Cams, Yamaha Road Star

 

After the cover is installed, check that the cams are still aligned by sighting the marks previously made on the rear cam shaft with the circle-hole on the front cam. See photo above.

Now, stuff rags or rubber gloves into the engine case holes at the bottom of the cam area. This will stop small parts--especially the tiny keys and alignment dowels--from flipping into the crankcase.

 

Cam, oil delivery tube, Yamaha Road Star

 

Insert the cam oil delivery pipe as shown in the photo above. Be sure both its O-rings are seated before installing the pipe.

Next, bolt and torque the camshaft cover, using 7.2 ft-lbs (86.4 in-lbs). See photo above.

 
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