D.I.Y. Cam Chain Replacement

Discussion in 'Parallel Universe' started by Dieselboy, Sep 22, 2011.

  1. JRWooden

    JRWooden Long timer

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    First THANKS for doing this!

    ON the oil - Yes ...I think that IS normal ... the first oil fill after the teardown tops up that little tray under the harmonic balancer arm (whatever its called). After that, future oil changes leave that much old oil in the bike... 400 - 500 ml sounda about right....

    Also, If I were you I would double-check coolant ... it s hard to get all the bubbles out...
    After your test ride, run your hand (carefully) across the front of the finned area of the radiator and make sure it is uniformly hot. If not you still have air in system ....

    There is a thread here that I started with Joel was kind enough to offer advice on "burping" the cooling system:
    http://www.advrider.com/forums/showthread.php?t=691458
  2. Dieselboy

    Dieselboy Journey not Destination

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    Fantastic info! :thumb Thanks. I'm editing that back in to save someone some hassle perhaps. And then I'm going back to the garage.
  3. Dieselboy

    Dieselboy Journey not Destination

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    Joel says the book on this job is 8 hours. I did it in 5 days. I estimate 40 hours of actual wrench time BUT that was with pictures and intentionally going very slowly. I think I could have done this in 20 hours. And yes it is a great deal of work because of all the small details. So we really need to develop a master link solution.

    But the real culprit here, IMHO, is the cam chain tensioner. I don't trust it. I don't know if it is working properly. I'm going to keep my eye on it.





    Thanks for the vote, I will accept a lesser accolade of excellent parts changer. I decline the nomination for mechanic because I lack the ability to diagnose and that is what makes a mechanic. Once I knew what to change, I did it. It is the "knowing" that is more impressive, I think.
  4. JRWooden

    JRWooden Long timer

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    If they come out with a model of this that fits our bike I may be in for one...

    http://www.dragbike.com/dbnews/anmviewer.asp?a=6182&z=5

    It will become another maint. item, but it really can't fail if set up correctly ...
    It would also stop the cold-start slapping of the chain while oil pressure builds to the OEM tensioner ....


    The old Hondas of my youth all had "manually" adjusted cam chain tensioners ... and they all worked fine!
    You just had to remember do do it!
  5. Dieselboy

    Dieselboy Journey not Destination

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    +1

    I was just discussing Honda manual tensioners.
  6. Dieselboy

    Dieselboy Journey not Destination

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    Blue sky dawn. :clap

    26 miles. Test ride a success. :strum

    Quiet(er). I'm not detecting abnormal cam chain noises. No leaks that I can find.

    I did the JoelWisman method of bleeding the radiator last night. I don't know if you'll read this Joel but thanks!


    After the test ride, left her running until the fan came on. Let it run for an additional minute and the fan cut off before I turned the bike off.

    Checked the oil. Still sitting at 1/4 dipstick. I am hesitant to add any more considering I loaded 3.4 liters. I waited five minutes and checked it again seeing only nominal increase in level. I'll add small amounts over the next few days and see what happens.


    I declare victory! :beer


    391[​IMG]
  7. ebrabaek

    ebrabaek Long timer

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    I`d like to add the Suzuki DRZ to the Cam chain tensioner gone bad..... It is a well know fact to us.....DRZ riders.... that the spring exerts too much pressure over time....... and the manual one is just right.... I installed one on mine....two years ago.... have not have to touch it since.......:thumb:thumb

    Erling
  8. Indy Unlimited

    Indy Unlimited Long timer

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    Great Job DieselBoy !!! :clap:clap:clap:clap:clap:clap

    Did you determine how much the stock chain stretched over the new chain?
  9. HighFive

    HighFive Never Tap-Out

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    [​IMG]

    [​IMG]

    HF :thumb
  10. Bayner

    Bayner Long timer

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  11. itsatdm

    itsatdm Long timer

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    On the issue of cam chain tensioners, I have a manual one installed on my KLX, but it replaced a spring loaded ratchet type. This one is basically oil pressurized. Anyone know if this is a dead end galley?

    I do know that my bike has never hinted at chain rattle and the first time I hear it, it will get a new tensioner.
  12. JRWooden

    JRWooden Long timer

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    It doesn't appear to be a dead end galley....looks like it is along the route of oil getting to the top end of the engine.

    I think the way the tensioner is designed it that there is a (light) spring in the design which is then augmented by oil pressure, and some kind of a check valve...
    I do get the rattle now everytime I start the bike after leaving it overnight it stops with in a few seconds as soon as oil pressure builds. I wonder if a new tensioner would fix that... I kinda doubt it.... or maybe my checkvalve is leaking down?
    For $50 I may go get a new one and see ...


    Anyway here's the best picture I can find:

    Attached Files:

  13. 'Flagger

    'Flagger ..this space for rent..

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    Same here. But it has occurred for months, maybe years, in my case. I manage the issue by not whacking the throttle on initial start-up and forgetting about for the rest of the day.

    But, if you change the adjuster and it helps .... maybe you can do mine. :deal
  14. itsatdm

    itsatdm Long timer

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    The issue with oil flow was the thought of a manual tensioner blocking it.
  15. MoToad

    MoToad Been here awhile

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    OK. First, congrats, Dieselboy. How did you get 90000 miles on that bike? Is it European or something? But thanks eversomuch for the complete photographed breakdown. Printin the whole thing out and it's going into my file, just in case that day comes for me. (Long way from those miles as of yet!)
    The thing we're talkin about now is the whole tensioner issue. For many moons now mine starts with the rattle then disappears as the oil takes over. Within a second or so. This kinda indicates to me that the spring is not doing its job. Haven't had a look at it but if it is a 'light spring like people say and I am suspecting then it has probably lost its tension already due to heat and cooling and the like. Wondering if swapping it out for something a little heavier might ease that problem? But, frankly, as long as the oil pressure side of the gizmo is doing its part it probably doesn't really matter. Anyone? Anyone? Bueller? Anyone?:ear
  16. Dieselboy

    Dieselboy Journey not Destination

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    8.75

    EDIT: new digital caliper reads 8.83

    Round pin

    392[​IMG]
  17. Bayner

    Bayner Long timer

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    Thanks.
    I'm also going to need the width between the to outer 'guide' plates. (Basically the dimension the gear occupies between the chain sides). Still not having much luck though...
  18. Dieselboy

    Dieselboy Journey not Destination

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    Thanks.

    The mileage is from riding, a lot. :D

    No, it is a US model from the first boat.



    The consensus is that your rattle is from the tensioner losing its oil. The rattle goes away after the bike reloads on startup
    Mine no longer rattles at startup. I think either a manual adjust or a reservoir would do well for us. Hopefully someone will produce one soon. My advice prior to this job would be earplugs. My advice now is buy a new tensioner.
  19. Dieselboy

    Dieselboy Journey not Destination

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    7.45 between the outside plates.

    EDIT: bought a new digital caliper today and slapped it on the links: 7.29-7.35. IDK which is closer.
  20. JRWooden

    JRWooden Long timer

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