* . . . 91-03 Timing inspection hole and plug pics and app. dims

Note: The cam gear case has 11 Allen screws of various lengths. They will need to be replaced back in the same holes from which they were removed. So, their proper location will need to be marked upon removal. You make a drawing of the cam gear case on a piece of cardboard and then put them into the cardboard in the proper orientation as removed from the cover.

• Remove the Rocker Covers and Pushrods:
• Place a flat drip pan under the engine. It will leak oil when the cover is removed.
• Remove the Allen screws holding the cover on and place them on your piece of cardboard.
• Pull the case out slightly so that it un-attaches itself from it’s gasket and the engine case.
  • Depending on your foot control setup, you may have to remove the foot peg / foot brake pedal support or brake rod to fully remove the cover.
  • Note: The bushing alignment with the camshafts has a VERY close tolerance. That means that the cover will need to come straight out. There will be no side-to-side or up-down play in the cover.
  • Once the cover is out far enough to get a small screwdriver in there, continually push the cams back in towards the engine as you slowly edge the cover off starting with #2 cam.
  • #1 and #3 cams are behind #2 and will go back when you nudge #2.
  • Don't forget about #4 which is independent and can come out on it's own.¹⁾
  • Once the cover bushings are clear of each cam, the case can be slightly rotated out of position.
  • Also, you will need to remove a rubber oil line that attaches to the rear area of the case before the case can be completely removed. Since the clamp holding this oil line cannot be reused, you will need to purchase a new hose clamp when the case is re-installed.
• Remove and discard the gasket. Clean the case with brake cleaner.

Removing the Cams:

Place the transmission in 5th gear.

Rotate the engine by turning the rear wheel so that all cams are lined up exactly as shown in the diagram below. This is done best if the bike is placed on a lift in order to get the back wheel off the ground so it can be rotated by hand.

Once all cams are perfectly lined up, remove all 4 cams by pulling them straight out. Do not remove the #5 pinion gear (This gear actually is held in place with a large nut)

Note: The hydraulic lifters do not need to be removed. They will remain in there bores once the cams are removed.

Once all cams are removed, DO NOT rotate the engine. This will make it much easier to install the new cams in there proper position.