SuzukiSavage.com - Tensioner, starter gear, head plug... any tips?

Keifer

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Tensioner, starter gear, head plug... any tips?
09/19/20 at 13:21:09

I'm about to tackle all 3 at once, figure that's easiest, only have to drain the oil once.

For the Tensioner: I have a new one from Verslavy (thanks!), new cover gasket, the 3 bolt gaskets, and new exhaust gasket.

For the starter gear: I have the updated torque gear, two new washers for that idler, a new cover gasket, and I'm going to take the cover to a machine shop to take that 1/2" out of the boss.

For the head plug: New verslavy head plug, and Honda bond. I will only tighten the nuts hand tight on reassembly, and use the cardboard method to keep track of bolts. Do I need to replace the 'figure-8' gasket?

Anything I'm missing or I should take care of while it's all apart? Thanks for any advice!

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justin_o_guy2

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Re: Tensioner, starter gear, head plug... any tips
Reply #1 - 09/19/20 at 14:10:57

My Figure 8 gasket survived several removals. As long as nobody Almost gets it where it belongs and tightens down on it,, no reason to not keep it. Just feel of it. Its Gottsta stand a bit proud of the groove to seal,, if its not mashed and mangled and stands a bit proud, clean it and slap it back in.
Dont put sealer on places that dont have mating surfaces on the head cover.
Make sure ya get that middle bolt in before ya set the head cover in and get the upside down bolt puzzle solved. There are some trick solutions to getting a proper amount of sealer down. I need a refresher,, so, sorry,,

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verslagen1

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Re: Tensioner, starter gear, head plug... any tips
Reply #2 - 09/19/20 at 17:01:26

Keifer wrote on 09/19/20 at 13:21:09:

For the starter gear: I have the updated torque gear, two new washers for that idler, a new cover gasket, and I'm going to take the cover to a machine shop to take that 1/2" out of the boss.
!

Don’t put washers on the idle gear. It goes on the torque limiter gear

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Keifer Junior Member Offline SuzukiSavage.com Rocks! Posts: 66 Canada	Re: Tensioner, starter gear, head plug... any tips Reply #3 - 09/29/20 at 12:23:06 Old tensioner. Probably didn't have much time left.
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Keifer

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Re: Tensioner, starter gear, head plug... any tips
Reply #4 - 09/29/20 at 12:25:15

New tensioner. Using the first hole, there was almost full extension, so I moved to the 2nd hole. It's right at max compression. I don't think I forced it, but is it possible to 'overstress' the cam chain? Also, clymers has two torque values for the set bolt/plate bolt, which is the bolt called in the 2nd hole?

(note the circlip is in I did it after this picture)

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Keifer Junior Member Offline SuzukiSavage.com Rocks! Posts: 66 Canada	Re: Tensioner, starter gear, head plug... any tips Reply #5 - 09/29/20 at 12:26:59 One further question: This is my first time doing gaskets on the case... I plan to do it dry (with new oem gaskets) but as long as the old material is removed, some clean oil on the mating surfaces is okay right? thanks
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verslagen1

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Re: Tensioner, starter gear, head plug... any tips
Reply #6 - 09/29/20 at 14:52:54

Keifer wrote on 09/29/20 at 12:26:59:

One further question: This is my first time doing gaskets on the case... I plan to do it dry (with new oem gaskets) but as long as the old material is removed, some clean oil on the mating surfaces is okay right? thanks

yes, I'd recommend it. you'll be able to reuse the gasket the next time.

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verslagen1

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Re: Tensioner, starter gear, head plug... any tips
Reply #7 - 09/29/20 at 14:55:39

Keifer wrote on 09/29/20 at 12:25:15:

New tensioner. Using the first hole, there was almost full extension, so I moved to the 2nd hole. It's right at max compression. I don't think I forced it, but is it possible to 'overstress' the cam chain? Also, clymers has two torque values for the set bolt/plate bolt, which is the bolt called in the 2nd hole?

(note the circlip is in I did it after this picture)

I think it will go out a couple of clicks, at least that's what I normally see.

ITEM N-m | ft-lb
Cam chain
tensioner/adjuster bolt 8.0 12.0 | 6.0 8.5

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Keifer Junior Member Offline SuzukiSavage.com Rocks! Posts: 66 Canada	Re: Tensioner, starter gear, head plug... any tips Reply #8 - 09/30/20 at 06:22:05 Thanks for that. I plan to have the case machined with the measurements from your other thread, does the hole For the torque limiter shaft need to be drilled as well? Or just the 1/2” material on the support.
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28749 L.A. California Gender:	Re: Tensioner, starter gear, head plug... any tips Reply #9 - 09/30/20 at 07:11:51 Keifer wrote on 09/30/20 at 06:22:05: Thanks for that. I plan to have the case machined with the measurements from your other thread, does the hole For the torque limiter shaft need to be drilled as well? Or just the 1/2” material on the support. I would advise you to check your shaft diameter.
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eau de sauvage

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Re: Tensioner, starter gear, head plug... any tips
Reply #10 - 09/30/20 at 15:40:10

You don't need to purchase a new clutch cover gasket because the OEM one is coated metal and will cope with very many removal and reinstalls.

I purchased a cheap OEM ones but they're just normal fibre gaskets and I quickly realised they are not worth the paper they're made from and never used it. The S40 gets hot and will likely bake a normal paper gasket.

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Keifer

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Re: Tensioner, starter gear, head plug... any tips
Reply #11 - 10/01/20 at 12:08:36

Unfortunately I purchased oem gaskets already, which happen to be the paper variety. Next time I'll look for the metal part numbers.

In case anyone reads this in the future, you do not need to remove the foot pegs or sidestand to remove the stator cover. A 3" socket extension and a 1/4" u-joint works for that one pesky bolt behind it.

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Keifer

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Re: Tensioner, starter gear, head plug... any tips
Reply #12 - 10/01/20 at 12:09:26

The limiter fits in easily, no rotor notch required. Perhaps the rotor is smaller on older models...

In this photo, you can see the torque limiter and idler gear do not line up perfectly. Is there some other difference in the '96+ I'm missing?

The diameter of the shafts are all the same, but you can see the length of the TL shaft here. It looks like the inner hole in the cover boss may also need to be drilled deeper... Any chance anyone happens to have a late model stator cover lying out who could measure the depth of that hole for me??

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Keifer

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Re: Tensioner, starter gear, head plug... any tips
Reply #13 - 10/01/20 at 13:04:18

If there's no difference on the engine case side, then most I can reason why it won't line up, is there must be a difference of the idler gear. The old and new ones have very similar part numbers, 12612-24B01 vs 12612-24B03 in the newer bikes. Is the width at the gear centre different to space it further from the engine case?

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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28749 L.A. California Gender:	Re: Tensioner, starter gear, head plug... any tips Reply #14 - 10/01/20 at 13:09:34 maybe you have the idle gear upside down?
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