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-   -   D.I.Y. Cam Chain Replacement (http://www.advrider.com/forums/showthread.php?t=727687)

Dieselboy 09-22-2011 02:54 PM

D.I.Y. Cam Chain Replacement
 
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EDIT: See Page 4, POST 56 to get to the beginning of actual tear down.
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EDIT: See Page 10, POST 141: chadams has a master link solution in progress.
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EDIT: See Page 11, POST 161: Joelwisman offers tech insight to cam chain stretch.
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So tech says chain is stretched slightly.

No measurement but I trust the eval. She’s running rough and does have a chatter at idle when hot.

What to do? Well, Joel says its an 8 hour job. I’ll give a 24:1 transposition and give it a whirl.

I have the maintenance DVD. (Haven’t looked at it yet.) I ordered the Haynes Manual yesterday.


Parts went on order today:


Item Part Quantity Part Number Cost
3 GASKET RIGHT 1 11147670688 $15.00

ENGINE RIGHT

1http://dieselboy.smugmug.com/2009/20...ineRight-M.gif


Item Part Quantity Part Number Cost
7 Gasket set, cylinder 1 11128520621 $68.97
head cover

VALVE COVER

2http://dieselboy.smugmug.com/2009/20...lveCover-M.gif


Item Part Quantity Part Number Cost
6 GEAR WHEEL 2 11317708198 $42.01 EDIT: DID NOT NEED THE GEARS.
8 GUIDE RAIL 1 11317690494 $7.74
11 TIMING CHAIN 1 11317690475 $84.39
12 CHAIN TENSIONER 1 11317690493 $10.80
7 Bearing screw 1 11317676592 $4.98 EDIT: REUSED OLD SCREW.

TIMING GEAR

3http://dieselboy.smugmug.com/2009/20...R%20copy-M.gif


Item Part Quantity Part Number Cost
1 GASKET LEFT 1 11117707906 $24.10

ENGINE LEFT

4http://dieselboy.smugmug.com/2009/20...gineLeft-M.gif


Item Part Quantity Part Number Cost
07 Gasket, oil pan 1 11117707905 $28.93


OIL PAN

5http://dieselboy.smugmug.com/2009/20...n%20copy-M.gif



Plus a tube of sealant.


I have torque wrenches. I have a garage. I have stayed at Holiday Inn Express this month....What am I missing?


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EDIT: I reused all the old seals and o-rings but I should have also orded:
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exhaust header flange gaskets
cam sensor o-ring
coolant lines o-rings
valve cover o-rings
out put shaft seal for counter sprocket
shaft seal for gear shift

Camel ADV 09-22-2011 04:12 PM

Will be watching closely as mine's making more and more noise all the time.

trizzo 09-22-2011 04:27 PM

any possibility you can take pics of the project and caption the process?

Dieselboy 09-22-2011 04:37 PM

Quote:

Originally Posted by trizzo (Post 16914886)
any possibility you can take pics of the project and caption the process?

I plan to. Unless of course I screw it up then I'll disavow all knowledge of the event....:evil

Rafiki 09-22-2011 04:44 PM

Quote:

Originally Posted by trizzo (Post 16914886)
any possibility you can take pics of the project and caption the process?

Step by Glorious step.
with photos.
good and bad.

and don't forget the beer.

YetiGS 09-22-2011 04:57 PM

:lurk This could be really interesting... :lol3

tkent02 09-22-2011 05:01 PM

Quote:

Originally Posted by Dieselboy (Post 16914165)
So tech says chain is stretched slightly.

No measurement but I trust the eval. She’s running rough and does have a chatter at idle when hot.

What to do?

Just curious, what is the mileage on this engine? Is the chain worm beyond the limits that the tensioner can compensate for?
Is there a problem with your tensioner, too?
Cam chains in Cheap Japanese Motorcycles used to run fine for 100,000 miles and more.
But then again so did wheel bearings.

Dieselboy 09-22-2011 05:27 PM

Quote:

Originally Posted by tkent02 (Post 16915119)
Just curious, what is the mileage on this engine?

92,000miles

Quote:

Originally Posted by tkent02 (Post 16915119)
Is the chain worm beyond the limits that the tensioner can compensate for?

Yes

Quote:

Originally Posted by tkent02 (Post 16915119)
Is there a problem with your tensioner, too?

Yes. Tensioner was bad. It has been replaced. (34,000 & 88,000) Suspect this was the root cause of the cam chain stretch.

Quote:

Originally Posted by tkent02 (Post 16915119)
Cam chains in Cheap Japanese Motorcycles used to run fine for 100,000 miles and more.
But then again so did wheel bearings.

Ich verstehe nicht :lol3

Dieselboy 09-22-2011 05:36 PM

I had toyed with the idea of contacting BMW NA :norton and offering a high-mileage GS for QA historical data :deal. But.....I'd rather be riding and I want this chain fixed so I can get back to it.

YetiGS 09-22-2011 06:45 PM

Quote:

Originally Posted by Dieselboy (Post 16915348)
I had toyed with the idea of contacting BMW NA :norton and offering a high-mileage GS for QA historical data :deal. But.....I'd rather be riding and I want this chain fixed so I can get back to it.

Have you heard anything about a new design a CAM chain tensioners? How hard are they to replace? Symptoms of the tensioner going bad? How many fibers in a shredded wheat biscuit? :lol3


Sorry for the questions, just curious.

Dieselboy 09-22-2011 07:05 PM

Quote:

Originally Posted by YetiGS (Post 16915806)
Have you heard anything about a new design a CAM chain tensioners?

No

Quote:

Originally Posted by YetiGS (Post 16915806)
How hard are they to replace?

The current one just screws into place. No fuss. [EDIT: I did reload it with oil prior to install.]

Quote:

Originally Posted by YetiGS (Post 16915806)
How many fibers in a shredded wheat biscuit? :lol3

African or European? :rofl

YetiGS 09-22-2011 09:05 PM

Quote:

Originally Posted by Dieselboy (Post 16915971)
No



The current one just screws into place. No fuss.



African or European? :rofl

:lol3

Huh, I wonder if replacing the tensioner every 20k or so miles would be good preventative maintenance.... :dunno

LukasM 09-23-2011 03:09 AM

Damn Nick, I didn't know you had THAT many miles on it! :eek1:clap

Is there any reason why it wouldn't be possible to replace the chain without taking the whole engine apart, e.g. split it and put in a master link? I would think that there is nothing unique about the BMW chain, so it would be a matter of finding an industrial supplier that can match the pitch, roller diameter etc. Or maybe from another bike?

Cheers,
Lukas

PS: Stator has been rebuilt and is now on the way to me. Cost $165 + shipping so not too bad. I will post some pics so we can see the quality and compare it to the Electrosport offering.

Dieselboy 09-23-2011 04:42 AM

Quote:

Originally Posted by LukasM (Post 16917669)
Damn Nick, I didn't know you had THAT many miles on it! :eek1:clap

Yeah, I get that a lot. What can I say, I like the bike.

Quote:

Originally Posted by LukasM (Post 16917669)
Is there any reason why it wouldn't be possible to replace the chain without taking the whole engine apart, e.g. split it and put in a master link? I would think that there is nothing unique about the BMW chain, so it would be a matter of finding an industrial supplier that can match the pitch, roller diameter etc. Or maybe from another bike?


Because the OEM chain is continuous, the engine must be cracked to install a new one. While I did consider trying to find a master link solution, the additional problem is internal wear on the guides. If you look at the pics (Timing Gear #12 & 17), the guide rail and tensioner are likely worn and must be inspected. Since I'm in there anyway, I'll just replace them. Plus, I don't like being the crash test dummy in the master link conversation even if I could find one.


Quote:

Originally Posted by LukasM (Post 16917669)
PS: Stator has been rebuilt and is now on the way to me. Cost $165 + shipping so not too bad. I will post some pics so we can see the quality and compare it to the Electrosport offering.

Glad that appears to have worked out. Keep us informed. I have a feeling more will be needed.

Dieselboy 09-23-2011 04:46 AM

Quote:

Originally Posted by YetiGS (Post 16916835)
:lol3

Huh, I wonder if replacing the tensioner every 20k or so miles would be good preventative maintenance.... :dunno

Lost Rider actually commented that this might be a good idea every 30,000. Until this widget gets re-engineered, I think that will be my new policy.


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