Motorcycle Repair: Kz 1000, silicone sealants, camshaft timing

Question
hey Mark
I just traded a guy an old junk car for a 1978 Kawasaki LTD 1000. Its been sitting for a long time. I was able to get it started just long enough to convince me that it was worth the trade. I decided to make this a project bike. My first. I know my way around tools however I never took apart a Motorcycle engin befor. This bike appears to be stock with no modifications. I know that the head gasket is blown and the carb is in need of some work. I have pulled the carb and will have a shop in town rebuild/clean/tune and balance it. I want to put four individual air filters on it cause I like the look. Anyway I purchased a shop book on vintage Jap bikes but it covers a lot of bikes and the info is not really spacific to my bike a lot of times. I have started breaking down the motor so to replace the gaskets.
The book I have says to tie the cam chain to the frame with a wire so that it wont fall into the engin bottom. My question is this with the chain tied to the frame how do I get the cylender head off without untieing the chain and dropping it in to the engin? Also do the gaskets need a sealer or some kind of cement? Do all the gaskets need replaced?
fstrujillo@usa.net  

Answer
Hi Ray,

If you're removing the head to replace gaskets, dropping the camshaft timing chain into the crankcase is not a worry. Reach in and remove it upon reassembly. Feed the chain through the head and then use the wire act until a camshaft can support the chain. If necessary, use a magnet retreiver tool to extract the chain.

While performing this job, the cylinder base gasket, oil passage o'ring seals, and camshaft timing chain tensioner pads should also be replaced.

Over time, camshaft end caps become brittle from heat. Replace the four rubber caps and use Kawasaki Bond sealant on cap's sealing surfaces. Use same sealant on gaskets where service manual specifies such use. Do not use Silicone sealants or cements.

When reassembled and prior to starting the engine, carefuilly rotate the crankshaft a few revolutions by tool on crank end to ensure cam timing is correct. Check cold engine compression to verify the sealing properties of each combustion chamber. New gaskets will change valve clearances. Measure all valve clearances and adjust as necessary. Start engine and warm to operating temperatures. Retorque cylinder head fasteners after engine has cooled to room temperature.

Follow service manual instructions closely.

Respectfully,
Mark Shively