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Old 09-22-2011, 02:54 PM   #1
Dieselboy OP
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D.I.Y. Cam Chain Replacement

************
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

1


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

VALVE COVER

2


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

3


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

ENGINE LEFT

4


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


OIL PAN

5



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
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Old 09-22-2011, 04:12 PM   #2
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Will be watching closely as mine's making more and more noise all the time.
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Old 09-22-2011, 04:27 PM   #3
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any possibility you can take pics of the project and caption the process?
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Old 09-22-2011, 04:37 PM   #4
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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....
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Old 09-22-2011, 04:44 PM   #5
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Quote:
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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.
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Old 09-22-2011, 04:57 PM   #6
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This could be really interesting...
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Old 09-22-2011, 05:01 PM   #7
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Quote:
Originally Posted by Dieselboy View Post
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.
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Old 09-22-2011, 05:27 PM   #8
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Quote:
Originally Posted by tkent02 View Post
Just curious, what is the mileage on this engine?
92,000miles

Quote:
Originally Posted by tkent02 View Post
Is the chain worm beyond the limits that the tensioner can compensate for?
Yes

Quote:
Originally Posted by tkent02 View Post
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 View Post
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
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Old 09-22-2011, 05:36 PM   #9
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I had toyed with the idea of contacting BMW NA and offering a high-mileage GS for QA historical data . But.....I'd rather be riding and I want this chain fixed so I can get back to it.
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Old 09-22-2011, 06:45 PM   #10
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Quote:
Originally Posted by Dieselboy View Post
I had toyed with the idea of contacting BMW NA and offering a high-mileage GS for QA historical data . 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?


Sorry for the questions, just curious.
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Old 09-22-2011, 07:05 PM   #11
Dieselboy OP
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Quote:
Originally Posted by YetiGS View Post
Have you heard anything about a new design a CAM chain tensioners?
No

Quote:
Originally Posted by YetiGS View Post
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.]

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How many fibers in a shredded wheat biscuit?
African or European?
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Old 09-22-2011, 09:05 PM   #12
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Originally Posted by Dieselboy View Post
No



The current one just screws into place. No fuss.



African or European?


Huh, I wonder if replacing the tensioner every 20k or so miles would be good preventative maintenance....
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Old 09-23-2011, 03:09 AM   #13
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Damn Nick, I didn't know you had THAT many miles on it!

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.
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Old 09-23-2011, 04:42 AM   #14
Dieselboy OP
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Damn Nick, I didn't know you had THAT many miles on it!
Yeah, I get that a lot. What can I say, I like the bike.

Quote:
Originally Posted by LukasM View Post
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 View Post
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.
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Old 09-23-2011, 04:46 AM   #15
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Huh, I wonder if replacing the tensioner every 20k or so miles would be good preventative maintenance....
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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