SuzukiSavage.com - Replace time chain

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Replace time chain (Read 120 times)

Willem

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DIY for fun!

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The Netherlands
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Replace time chain
06/19/15 at 03:51:15

Hi,

I'm very glad tot found this forum! A lot of usefull information for me, read it all almost!

My project is a 1992 LS650 and i'm working on the engine right now. Got the engine off the bike and my tensioner is allmost off! Embarrassed

(see pic)Now I will have to replace the timing chain and tensioner I guess. Reading all the info here helped me a lot but there is no full manual for replacing the timing chain. Even the clymer handbook isn't going to that whole process either.

I hope someone can refer to a link or give me some advice to start the fun!

For example i'm not sure if I need to remove the whole top of the engine and what's the best procedure for it.

Thanx a lot!

(Living in Holland so excuse for the language.... Grin

)

Willem

20150614_142238_resized.jpg

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Dave

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SuzukiSavage.com
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Camp Springs, Kentucky
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Re: Replace time chain
Reply #1 - 06/19/15 at 04:17:22

Here is the cam chain thread links....there is plenty of reading:

http://suzukisavage.com/cgi-bin/YaBB.pl?board=tech;action=display;num=1176999168

You can get some additional mileage out of your existing chain if you weld on an extension to the plunger. The chain is not beyond the wear limit when the stock tensioner becomes over-extended. Also if your existing tensioner is not damaged....there is no need to buy a new one....then to see if the bore has become oval near the end of the tensioner.

Someday I will be old......But not today!

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justin_o_guy2

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What happened?

Posts: 55279
East Texas, 1/2 dallas/la.

Re: Replace time chain
Reply #2 - 06/19/15 at 09:16:05

Just fixing the tensioner saves SO much work. And money...
The Suzuki maintenance manual says
Dont use an impact
For the clutch pack. Well, JUDICIOUS use is okay. Of course never apply power tools to anything you haven't got threads started on.
Be aware that some stuff is left hand thread.
Some jam a penny in the gears, I used leather.
While it is on the bench, great time to check valves.
Blow the crud out of the spark plug hole.

The people never give up their liberties but under some delusion.- Edmund Burke.

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carcaveman

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Tucson, AZ
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Re: Replace time chain
Reply #3 - 06/19/15 at 19:38:52

I just went through the process of replacing the chain. You will need to remove the top cover assy covering the cam shaft in order to get the top of the chain. I had to go a step further and remove the valve assy in order to replace the cam chain guides. On my bike I did not need to remove the clutch pack as it was possible to remove the main drive gear nut (left handed thread). There are great write ups on this forum and download the manual. You should also print out the bolt pattern for the valve head. It's a good time to deal with the oil plug. It will be obvious when you access the top assy.

2001 Suzuki Savage

Yamaha Petcock - Done
Chain Tensioner - 8.5 mm (New Chain)
Oil Plug - Done
Handlebars - In progress

PS 24:1
(It's all His.)

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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Replace time chain Reply #4 - 06/19/15 at 21:08:21 read up before popping that head cover off.
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AsphaltMan YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 11	Re: Replace time chain Reply #5 - 06/24/15 at 16:14:31 oil plug?
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