D.I.Y. Cam Chain Replacement

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

  1. Dieselboy

    Dieselboy Journey not Destination

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    Again, good post. So initial rattle no major issue (as I always believed prior to this thread.) But now mine does not rattle at all-- even better.


    For the record my left cover was tightened per the book (both sequence and torque) and that is what I show in the pics.
  2. JRWooden

    JRWooden Long timer

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    I'm not sure when mine started ... it did NOT do it when it was brand new, but only started sometime later....
    It does only do it on a cold start for 1-3 seconds.....

    DB: Did you replace your tensioner assembly during this rodeo?
  3. Dieselboy

    Dieselboy Journey not Destination

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    Tensioner was replaced two weeks prior to this surgery. And it will get replaced in 25000 miles regardless.
  4. JRWooden

    JRWooden Long timer

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    Seems like cheap insurance ... esp. after seeing the "photo shoot" :lol3
  5. Y E T I

    Y E T I Unpossible

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    You should do a photo DIY for replacing the tensioner.



    :hide
  6. Dansrc51

    Dansrc51 I need a cape....

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    :stupid +1
  7. zaner32

    zaner32 In over my head

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    Great job. I'll have to print it and keep for reference. :freaky

    The dealer changed the tensioner as the bike was rattling considerably until it warmed up. At startup it would rattle a bit, and get quiet. After that, it would cycle every second or so rattling, quiet, rattling, quiet. and so on until warmed up. They said the tensioner was 'bleeding' too much oil? I haven't had a chance to ride it too much since I got it back. Having fun with the DR350 on the greasy trails:evil
  8. Rafiki

    Rafiki Some Dude

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    First off,Excellent job !! :thumb

    Second,on the coolant bleeding issue;if you have an old radiator cap,you could drill a hole in the top of it,attatch and seal a "nipple"(something to attatch a vacuum hose to) then attatch a hose and vacuum pump to it.

    once you fill it,put it under vacuum-this should draw all the ait bubbles to the radiator cap.
    Rinse/repeat till it stays full after vacuum.
  9. Dieselboy

    Dieselboy Journey not Destination

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    No measurement made. I didn't think I could get an accurate measurement without investing more time than I was willing to invest.
  10. rritterson

    rritterson Been here awhile

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    Fantastic write up!

    Side question: for rivet-type master links, can't one simply grind the rivet heads off, install the chain, then reuse the existing plates from the disassembled link and just replace the pins?
  11. chadams

    chadams Been here awhile

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  12. mischief

    mischief misadventurer

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    Why do we need master links?
    Is there any reason to replace more than one pin? Pushing one pin out will break the chain, attach it to the old one and pull it around then replace the pin. I wouldn't think it would be that hard even if someone had to custom machine new pins

  13. chadams

    chadams Been here awhile

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    How many links are there in the f800gs timing chain? Thanks
  14. chadams

    chadams Been here awhile

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    f800gs part number.... finally found one 98XRH2015

    Now where to but one with a master link

    http://www.orakorbike.sk/!img/upload/file/morse_retaze.pdf


    PS: Why I have so much interest in cam chains at the moment. My f800gs has just under 90,000km, with a very loud cam chain and a broken chain jump guard above the exhaust cam sprocket. I don't wan't to split the case, but I'm yet to find a master link for this chain.
  15. LukasM

    LukasM Long timer

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    Mate that is an amazing find!!! Morse is a part of the Borg Warner group so this makes perfect sense!! :clap:freaky

    I did some more searching and found which other bikes use that same chain:

    [​IMG]


    I haven't been able to find a split link for it yet, most OEMs seem to use/sell that chain in an endless configuration.

    But it's a big step in the right direction so let's all keep digging!
  16. TwIsTeD OfF

    TwIsTeD OfF The new hottness

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    A KTM cam chain looks like a mini drive chain. no "extra" link plates in the center. If you can reuse those a masterlink and a rivit tool are easy to get. Munn racing (ktm dealership in TX) stocks both.

    *** edit**** I didn't see until after I posted those are newer year models than I have worked on. ****
  17. chadams

    chadams Been here awhile

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    I have ordered a stock cam chainand have been playing with the old one. If you use a chain press and slide the pin to the outer plate it can be re-used / re-linked. I've had about nine practice runs on the old chain without any problems. Worst case the chain has a tight spokt and runs a few links driving the valves through the piston. I'd rather give it a shot first then stripping the motor down and removing the crank.
  18. Motorfiets

    Motorfiets Long timer

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    So you just drive it out to the outer plate then push the pin back in?
  19. chadams

    chadams Been here awhile

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    Yes, that's what I've done on my practice runs, once the chain turns up, hopefuly soon (6 weeks express from Germany) I'll post some pics.
  20. Motorfiets

    Motorfiets Long timer

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    6 weeks!?! ouch.... where are you located?