1981 KZ650CSR

Hi all, I'm wanting to remove the valve cover to give it a proper clean and polish but can't remember if you can just undo all the bolts and lift it off or if you need to slacken the cam chain tensioner (or something) first.
I do have a manual but can't find it in the mess that is my shed!
Thanks for any help.

If you don't turn the crankshaft, then you shouldn't have to do anything >> just remove the valve cover >> the cam chain should just sit there.
For peace of mind after re-installing the valve cover & torquing it down, I would reset the tensioner by removing the cap & wedge, then reinstall.
You could take a pic of the cam chain immediately after removing the cover >> it should have some sag.

Kawasaki KZ650 service manual. jarlef z650. the 1981 KZ650 pdf manual is in the Files section.
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That's absolutely brilliant, thanks for the fast answer Martin.

Plus for reminding me about the files section. That's exactly the manual I can't find! :laugh:

Whenever I plan on removing the valve cover, I also service the timing advancer beforehand. So I go ahead & turn the crankshaft to line up the timing marks, then remove the valve cover. remove the cap & wedge prior to installing the valve cover.

Just an fyi. to turn the crankshaft, use a 17mm wrench (don't use the 14mm advancer bolt. there's a warning in the manual >> advancer damage can occur).

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The tensioner cap and spring should be removed before reinstalling the cover because there is a rub block in the cover which presses down on the chain. Failing to do this will result in the chain being over tensioned.

Well the cover is off!

I found out I’m missing the washer under the cap so I’ll need to track down one of those.
The cam chain was nice and quiet before so it can’t make too much difference.
No idea why the photo has attached upside down, it’s the correct way in my gallery. Sorry.

The washer should be available from the Kawasaki dealer & other places. Partzilla has a photo of it.


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Thanks again Martin.
I also need the washer for the lock bolt that retains the push rod. Do you think it's necessary to get the correct one or will an ordinary washer do?
Is it best to slacken the lock bolt before torquing the cap or does the lock bolt just hold the pushrod in place rather than actually locking it?

The lock bolt prevents the pushrod from falling down into the engine, such as when you remove the camshafts, but it doesn't actually lock the pushrod in place. so you can install it before torquing the cap.

The washer is listed as a banjo washer in the diagrams at partzilla, so whatever you get probably needs to seal the bolt.

ps: I'm assuming you read Nessism's reply. In regards to my first reply, for peace of mind it's probably best to remove the cross-wedge first, then torque down the valve cover. I've had the valve cover off without turning the crankshaft & I didn't feel any tension from the cam chain when reinstalling the cover, but I still reset the tensioner. Usually though, I turn the crankshaft for whatever reason whenever the valve cover is off, so you must remove the cross-wedge before installing the cover to avoid stretching the cam chain.
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