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Message started by matt on 04/14/20 at 11:48:22

Title: another chain tensioner pic
Post by matt on 04/14/20 at 11:48:22

Hello. Just thought i would share my tensioner. Im sure you seen a million but to me, is beautiful inside.

With SO much time idle as of lately I started the search for the source of the noise that is driving me nuts, it led me this way since valves are checked in clearance.

Unfortunately I dont have means to access the chain to replace or check so tensioner it is.. for now..
Anyway since I already have an older (unused) gasket hanging on my wall, I thought why not take a peek. Its on 20k mi after all :-? :-X More gasket to come although it would be very nice to do in one go-around.

Its been a few years since i've gotten my hands greasy and dang it feels nice to get dirty and tear shat apart. ;D :D

measured 20.25mm out >:(

http://https://i.postimg.cc/fLCyvGGS/chaintensioner20.jpg

Title: Re: another chain tensioner pic
Post by Armen on 04/14/20 at 11:59:13

It's dead, Jim.

Title: Re: another chain tensioner pic
Post by Tacopimp on 04/14/20 at 16:21:29

fix it now with a modded tensioner, or else kiss that bike goodbye.

Title: Re: another chain tensioner pic
Post by norm92de on 04/14/20 at 17:26:07

Congrats you caught it in time!

No problem if you put in a Versy extension. :)

Title: Re: another chain tensioner pic
Post by eau de sauvage on 04/14/20 at 17:35:09

I just saw the batman icon and did not look at the name, I was just about to post 'how can this be possible, batman'? when I see it's not batman it's mattman.

I've had a versy tensioner ready to drop in for a while and last time I looked there was still 6mm of travel to go, it dropped down to the 6mm but it stayed there for a while so last time I opened her up I put the versy on anyway on the first hole and said to the gf, whose bike it is, that even if the chain gets a bit loose at least the tensioner won't pop out and destroy the bike, so do keep an ear out for any extra sounds.

I've had a spare Athena green paper clutch cover gasket sitting here ready to use but even though I've had the cover off now about eight times, the original one is still good, and in fact I will never be using an after market gasket because I now see why the original is made of coated metal, it does not stick and it does not leak and it goes on and on, and makes taking the cover off much easier.

The clutch cover gasket is one OEM part that is well worth the cost. Same with the fuel hoses on a gs500, they're about $150 for all three, as opposed to $20 for do it yourself hoses.

Title: Re: another chain tensioner pic
Post by Hiko on 04/15/20 at 01:52:59

Just to be clear here The original gasket can be used over and over?
I have time on my hands and would like to look at the tensioner but dont have access to a new gasket due to this lockdown thing.

Title: Re: another chain tensioner pic
Post by Tacopimp on 04/15/20 at 08:50:26

083D2E2A222A4F0 wrote:

Just to be clear here The original gasket can be used over and over?
I have time on my hands and would like to look at the tensioner but dont have access to a new gasket due to this lockdown thing.

Really depends on the condition its in. If you never opened it up there is a good chance that when you pop the cover off the gasket will tear and pieces of it may be left behind that you would need to scrape off and put on a new gasket. If you hear the noise it would be a good idea to stop riding and order a gasket and modded tensioner and switch it out to be safe.

Title: Re: another chain tensioner pic
Post by Tocsik on 04/15/20 at 13:25:40

I've had my cover off twice and reused the original gasket both times. Still have the new one I bought when doing the tensioner and keep it "just in case". But, as already state, depends on each circumstance.

Title: Re: another chain tensioner pic
Post by Hiko on 04/16/20 at 21:43:33

I took my clutch cover off and the gasket came off clean The adjuster was out 14mm the bike has done 9477Kms so only 4mm to go .
This has made me a little nervous so I decided to do some thing about it
Here is what I came up with
The post that supports the tensioner has a long thread into the engine block so by putting 3mm of washers behind it it is possible to run a guide arm over the 12mm part of the post and extend the tensioner
It all fits OK and hopefully will make the tensioner safe from overextending
The guide looks to be in good shape from what I could see of it
The extension of the tensioner would depend on the bend of the guide so it may have been extended quite a way from new
As has been said before not a very good design

Title: Re: another chain tensioner pic
Post by eau de sauvage on 04/17/20 at 04:51:37

5B6E7D7971791C0 wrote:

Just to be clear here The original gasket can be used over and over?
I have time on my hands and would like to look at the tensioner but dont have access to a new gasket due to this lockdown thing.

Yes, if it's the original one it is designed to be reused many times. It is coated metal. I've had mine off 6 times at least maybe more over the past few years. Still looks new. I think someone dropped one recently on their tank and damaged it. The tank that is not the gasket.

Looks like the tensioner is a bit of a crap shoot, our one has done 40k kms, and is still on the first hole, gonna be checking it soon.

Title: Re: another chain tensioner pic
Post by DragBikeMike on 04/17/20 at 12:42:46

Hey Hiko, that's a pretty clever contraption you came up with. If possible, can you post a picture with it installed? Can you keep us posted on how it works out, maybe do a test report?

Thanks, Mike

Title: Re: another chain tensioner pic
Post by Hiko on 04/17/20 at 16:55:04

Here it is installed I removed the far out hole as by the time it got out there the two sides of the chain would be rubbing together
I now have at least 18 mm of travel to go before it hits the end of the slot
It will be a few weeks before I get to do any riding with this lockdown thing

Title: Re: another chain tensioner pic
Post by Hiko on 04/18/20 at 00:51:05

I have decided to abandon this method of curing my tensioner woes
I feel their is insufficient clearance between it and the oil gallery inside the clutch cover [1mm] to prevent it tapping against the cover so at this stage I think I will just extend the plunger and do regular checks
The tiny tension pin into the thin plunger wall does not seem robust to me
as a real solution maybe I am wrong. I would have thought Suzuki after 34 years would have fixed this issue.

Title: Re: another chain tensioner pic
Post by Hiko on 04/19/20 at 21:02:41

Tensioner Contraption MK2

Revisited this with a redesign running the strap over the top There is just enough room there but had to trim the gasket where it protrudes into the clutch case I like this design better No circlip fitted in the pic

Title: Re: another chain tensioner pic
Post by philthymike on 05/09/20 at 08:44:38

Before.

Title: Re: another chain tensioner pic
Post by philthymike on 05/09/20 at 08:45:19

After.

Title: Re: another chain tensioner pic
Post by justin_o_guy2 on 05/09/20 at 12:07:29

I thiink trials have shown that removing the pawl has no ill effects and Seriously extends the life of the chain.
When the engine gets taller from heat, it pulls on the chain. IF that Pawl has just grabbed a new tooth, it will NOT give, and when the engine heats up, it gets taller, and strains the chain more..
There are several ways around that, but the most direct is, ditch the pawl,,
I think it is Batman who did it first.

Title: Re: another chain tensioner pic
Post by batman on 05/09/20 at 13:26:06

Guilty as charged, having never rode my bike gently , but I believe that the quality of cam chain has changed over time. My 95 didn't need an extension of the tensioner until 19,000 miles but since then has shown little to no further stretch by removing the paw and it's spring . Current mileage on the original chain is 39,000 miles (-starting it's sixth season - that 's if it wasn't 32F and snowing today ::)

Title: Re: another chain tensioner pic
Post by DragBikeMike on 05/09/20 at 14:56:45

Hey Mike, I'm lovin your cleanliness plugs. What are they made from? They look like they fit just right.

Title: Re: another chain tensioner pic
Post by justin_o_guy2 on 05/10/20 at 22:41:36

Batman...
You ditched the spring, too?
I wonder what the chain is doing as rpm change,,
I can track with ditching the Pawl,,
But I'm confused about being gutsy enough to toss the spring.
I know you have plenty of miles on it to prove it. I know it works..
I just don't understand how..
And Since it works
Why do manufacturers build these things with such self destructive tensioners?
Cam chain issues are common on lots of bikes, and apparently, needlessly.

Title: Re: another chain tensioner pic
Post by batman on 05/11/20 at 06:00:37

JOG , I went to a shorter and heavier spring , with the stock spring and the piston being pushed back into the body ,I was afraid because of the continued movement that it might bind or fail. Use of a shorter , stiffer spring with more open coils allowed more movement and slightly more pressure . There are two times when timing is retarded ,at cold startup and when the TDI reaches it's max advance (5000 rpm) ,the constant pressure I apply to the guide aids during both. Outside of a tuned air intake and a stock H-D muffler my bike is completely stock from the carb(highly tuned) to the exhaust header yet a WOT run a week ago produced a top speed of 94mph. I run 70 on highways with a healthy reserve for passing.

Title: Re: another chain tensioner pic
Post by justin_o_guy2 on 05/11/20 at 08:21:59

YOur answer to the tensioner issues is a really good one..
You could toss me all the right goodies to choose from amongst options and I would never get a carb Top Notch,, Im an 80% er,, at best.

Title: Re: another chain tensioner pic
Post by philthymike on 05/11/20 at 08:31:33

66606F13111612220 wrote:

Hey Mike, I'm lovin your cleanliness plugs. What are they made from? They look like they fit just right.

Those are hunks of plastic foam used for shipping fragile stuff like electronics items. I just ripped the foam to fit after testing it to see if engine oil would dissolve it. I tore the pieces a little big so they had to be squished into the mouse holes. The tension kept them from falling inside.