Damaged Cam Cap
Cut to chase version:
Can the cam caps be purchased individually, or does Kawasaki make you buy a whole new head if they are damaged?
Full Detail version:
I've been working on doing the first valve check/adjust on my 2009 Versys, and thought everything was going reasonably well, until the final torquing of the cam cap bolts. The two main cam caps went fine, but there was a snapping sound during the process of snugging the bolts on the end cap, the one by the cam gears.
I thought I'd maybe snapped a bolt, or pulled threads out of the aluminum head, but it turned out to be a crack in the cap. There's also some indication that the cap might have been just a hair out of alignment with the cam, Though how that could be possible with dowel pins to locate it, is kind of baffling to me.
At any rate, the cam cap is now damaged. The crack is in the area that would house the circumferential ridges that the service manual refers to as "thrust blocks", on Page 5-24. Does anyone know if this cam cap is available separately from Kawasaki? I'll start calling dealerships on Monday, but I have a sinking feeling that this part might not be available without buying the whole head assembly. And that's not a thrifty option.
Another possibility might be to have an experienced machine shop try to repair the crack. There's a high tech welding shop in town that specializes in joining more exotic alloys, and work that's more difficult and intricate. But, I'd prefer to just get a new cam cap, provided I don't have to buy a whole head assembly to get it.