SuzukiSavage.com - In the nick of time

Kropatchek

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Why more than 1
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In the nick of time
02/14/07 at 02:23:25

Herewith some pictures of a camchain/tensioner on the verge to separate.
http://www.ls-650.de/community/forum/YaBB.pl?num=1171335467

The tensioner pictures are speaking for theirselves: in the nick of time.

Note the following errors/mistakes done by the previous owner/workshop.

1) The locking plate of the camchaingearbolts is the wrong way around( it should cover the locating pin hole) and is not bent over. As a consequence of that error the bolts loosened-up and destroyed the thread in the camshaft.
2) The locking plate under the clutch nut has not been bent-over
3) The inside of the clutch shows oil that has been burned-up

All to increase our knowledge of the Savage engine

Greetz
Kropatchek Grin

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Never ask your bike to scream before her throat is warm.
'93 Sav in '96 ( yellow) looks

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Savage_Greg Serious Thumper Alliance Member Offline Don't go around your ass to reach your elbow... Posts: 7844 SW Washington State Gender:	Re: In the nick of time Reply #1 - 02/14/07 at 05:18:07 That is a mess. Thanks.
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Savage_Rob Serious Thumper Alliance Member Offline Mechanically Inclined Amateur Posts: 6972 Texas (Dallas area) Gender:	Re: In the nick of time Reply #2 - 02/14/07 at 05:19:06 Wow! Seriously just in time!
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franch Senior Member Offline I love YaBB 1G - SP1! Posts: 287	Re: In the nick of time Reply #3 - 02/14/07 at 08:03:02 thats about how far out mine was at 28000miles on the odometer. a close up may show all the cracks in the tensioner.
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SavageDude Serious Thumper Alliance Member Offline Posts: 561 OC_California Gender:	Re: In the nick of time Reply #4 - 02/14/07 at 09:08:24 So what lesson can we learn here? Pay attention to details. I would take picture of what I'm about to disassemble so at least I can use for reference when it's time to put it back together even if I have service manual next to me
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Ed L. Serious Thumper Alliance Member Offline "We All go a Little Crazy Sometimes" Norman Bates Posts: 2808 Sunny Florida Gender:	Re: In the nick of time Reply #5 - 02/14/07 at 15:46:06 Maybe it's me but the clutch nut looks like it has a crack in it also.
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Savage_Rob Serious Thumper Alliance Member Offline Mechanically Inclined Amateur Posts: 6972 Texas (Dallas area) Gender:	Re: In the nick of time Reply #6 - 02/15/07 at 06:20:02 Ed L. wrote on 12/31/69 at 16:00:02: Maybe it's me but the clutch nut looks like it has a crack in it also. Looks like it to me too.
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Savage_Greg Serious Thumper Alliance Member Offline Don't go around your ass to reach your elbow... Posts: 7844 SW Washington State Gender:	Re: In the nick of time Reply #7 - 02/15/07 at 07:58:01 I'll be darned. Good eyesight
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Savage_Greg Serious Thumper Alliance Member Offline Don't go around your ass to reach your elbow... Posts: 7844 SW Washington State Gender:	Re: In the nick of time Reply #8 - 02/15/07 at 12:56:27 Well, I'll be darned...I sure am glad that this subject came up. Here is the "In the nick of time" tensioner from the German site... Here is what I just found inside my case... Thanks.
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Savage_Rob Serious Thumper Alliance Member Offline Mechanically Inclined Amateur Posts: 6972 Texas (Dallas area) Gender:	Re: In the nick of time Reply #9 - 02/15/07 at 14:07:20 Still looks to be aligned but extended a bit, I guess. How many miles on it?
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Savage_Greg

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Re: In the nick of time
Reply #10 - 02/15/07 at 21:41:38

Well, considering that I've had more wrenching than riding for over a year, the bike has only 14K on it....

Hoping to do much more riding this year, but I wasn't aware of this tensioner issue and it's been 3 years since I was in there.

Today, I pulled everything out of the clutch side...

And here is a front view of the tensioner. The hole isn't worn out like in the German photo.

And there isn't any wear on the tensioner parts either.

Actually I am photographing the whole process, and I'll post a topic in the tech section when I get it all sorted out.

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verslagen1

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Re: In the nick of time
Reply #11 - 02/15/07 at 23:42:12

Hey Greg what I'm thinking about is how flimsey is the guide the attaches to the tensioner?

Maybe it needs a guide pin on the bottom of the tensioner and a slot machined into the guide to keep the angle near constant. The nick of time photo from the german site shows the tensioner dropping down almost into the gear. Anyway some sort of engagement between the two.

I like the idea of keeping the tensioner rod from coming out of it's housing at end of adjustment too.

But certainly, weld an extension on the end of the rod. It's looks to me that there is not much more then 1/2" between the 2 sides of the chain.

So there's the limit of how much further we can go. Do like slavy did, add an 1" of material and add a hole about 1/2" out. Can't go much further anyway.

Good luck, please post your progress. I'll be following your footsteps shortly.

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Kropatchek Serious Thumper Offline Why more than 1 cylinder? Posts: 1457 Alphen a/d Rijn Netherlands Gender:	Re: In the nick of time Reply #12 - 02/16/07 at 01:12:26 There's some nice pictures in this thread.: http://www.ls-650.de/community/forum/YaBB.pl?num=1168393837;start=all Greetz Kropatchek
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Reelthing

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Re: In the nick of time
Reply #13 - 02/16/07 at 04:43:49

hard page to get through - it looks like he has made 10 or so of the 2 rail tension adjusters TBKS3 but somewhat slower than people expected.

do you have yours yet?

also looks like he is doing the mod to the suzuki oem adjuster to keep it from coming apart - is that also something you ordered?

it seems he believes even at 60,000km and several manual adjustments the performance of the engine is not effected by cam chain stretch

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Savage_Greg

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Re: In the nick of time
Reply #14 - 02/16/07 at 05:15:34

verslagen1 wrote on 12/31/69 at 16:00:02:

Hey Greg what I'm thinking about is how flimsey is the guide the attaches to the tensioner?

Maybe it needs a guide pin on the bottom of the tensioner and a slot machined into the guide to keep the angle near constant. The nick of time photo from the german site shows the tensioner dropping down almost into the gear. Anyway some sort of engagement between the two.

I like the idea of keeping the tensioner rod from coming out of it's housing at end of adjustment too.

But certainly, weld an extension on the end of the rod. It's looks to me that there is not much more then 1/2" between the 2 sides of the chain.

So there's the limit of how much further we can go. Do like slavy did, add an 1" of material and add a hole about 1/2" out. Can't go much further anyway.

Good luck, please post your progress. I'll be following your footsteps shortly.

I don't really think that the guide is flimsey. The bracket that attaches to the tensioner is pretty stiff. To me, the problem seems to just be with the tensioner design.

And when I look at the guide, I get a little confused too. There appears to be very little wear. No cracks of any kind.

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