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Post by anonigma on Mar 9, 2010 17:24:11 GMT -6
As stated in a previous thread my timing chain broke and in the process broke some rocker arms. so i got a new head from ebay, now im about to split the case to put in a new timing chain. I have a clymer manual im going by.
Anyone done this? any advice? Is it possible that any permanent damage was done?
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Post by eaglerider on Mar 9, 2010 18:30:47 GMT -6
Have u removed the head yet? That would be where to look - this engine is a 0 clearence engine, so u have to check the valves to see if they are bent. And check the pistons also - bend a valve in the right position, and it can lock, and put a hole in the piston.
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Post by anonigma on Mar 10, 2010 7:53:56 GMT -6
The engine is completely tore down right now. The only damage appears to be the broken timing chain and rocker arms. The pistons have marks where they touched the valves but there's no holes. I got a complete head from eBay to use in case the old valves and head were bent when the breakage occured.
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Post by eaglerider on Mar 10, 2010 8:48:24 GMT -6
Make sure the valves move easily in the head - one or more could be slightly bent.
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Post by anonigma on Mar 20, 2010 19:15:06 GMT -6
Putting everything back together and I can't get the chain around the sprockets. It's almost like the chain is too short. I held it up to the broken one before I put it in and it looked to be the same. Valve adjuster screws are out. Chain tensioner is out. Am I missing something?
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Post by eaglerider on Mar 20, 2010 19:30:53 GMT -6
Did you read the directions in the manual? You have to align the gears and marks on the chain correctly, to set the timing, or you will be in trouble, and have to re-do it.
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Post by anonigma on Mar 20, 2010 21:32:36 GMT -6
I have a clymer manual. All it says is: "Lift up on the cam chain and slide the 2 camshafts through and seat them in the cylinder head. Engage the cam chain with the cam sprockets. " Then it talks about setting the timing by just lifting the cam chain off the sprocket. Sounds easy but I just can't get the cam seated with the chains on the sprockets no matter which way I have the cams turned. Either I'm an idiot or the chain is too small. Gonna double check everything in the morning. Then I guess I'll take it to a mechanic which is what I was trying to avoid in the first place.
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Post by eaglerider on Mar 20, 2010 21:52:56 GMT -6
I worked with GWK replacing a head, and had no problem with the chain. This may sound dumb, but where did you get the chain, and are you sure it is for the 454? If the info you sated is right, and the chain is on the crank gear correct, and not "hung-up somewhere, it sounds like you do not have the correct chain. There are marks on the chain, and "dots"on the cam gears for setting correct timing. If I remember correctly, there are 22 "links" between the dots on the cam gears, but make sure of this, as I don't have the manual in front of me. Our on-site manual should give good info, as it is an official Kawasaki manual, and somewhat more in-depth.
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Post by anonigma on Mar 20, 2010 22:44:00 GMT -6
Got it at the local bike parts store. They had to order it and I had to wait a week for it. They're an established and reliable shop but I suppose they could have made a mistake. I'm gonna double check the part numbers with them on Monday. I held it up to the broken chain and it looked the same but I did not count the links. I'll do that tommorrow as well.
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Post by anonigma on Mar 21, 2010 15:23:15 GMT -6
Good news is I got the chain on. Bad news is I'm an idiot. I guess this was a lesson in patience. Best I can figure is that it wasn't seated properly on the lower sprocket.
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Post by sctsgt on Mar 21, 2010 15:38:30 GMT -6
Sometimes all it takes is a break, then go back and try it again. I know that's how it worked when I changed out my starter. Would not go in or out for anything....then it just fell through into place.
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Post by eaglerider on Mar 21, 2010 19:42:34 GMT -6
I don't even want to think about how many times that has happened to me!!
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Post by anonigma on Mar 25, 2010 10:51:11 GMT -6
Oh lessons learned.... Heres a few more I'm in the process of learning. 1. Old side cover gaskets are a pain in the bottom to remove. 2. You should remove old side cover gaskets while the engine is out of the frame. Probably much easier. 3. Napa gasket remover spray doesn't work very well on these gaskets. But it will remove all the paint from the engine block stay tuned for more lessons to learn .....
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Post by anonigma on Mar 28, 2010 8:54:25 GMT -6
Got the bike running. Carbs need cleaning and new gaskets. Battery was dead. Other than that it seems to be ok. Rode it in the driveway but havnt road tested it yet.
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Post by anonigma on Mar 30, 2010 8:47:06 GMT -6
Bike is running but I'm having a strange issue. When I rev it up around 5000-6000 rpm or more it starts making noise that sounds like either the timing chain slapping around or maybe the valves. One time I just let it idle and it quit on it's on. Another time I turned it off and then back on and it was quiet again? Could this be the chain tensioner? (I reused the old one for now) or something else?
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Post by eaglerider on Mar 30, 2010 15:08:42 GMT -6
Could be, however, are your valves adjusted properly. This engine is rather noisey.
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Post by anonigma on Mar 30, 2010 16:50:20 GMT -6
Yes I adjusted the valves when putting everything back together. There's just something weird about this. I just rode around this evening for a couple of hours. Every time I would get it up above 6000rpm then slow down the chattering would be pretty loud and on 3 different occasions I turned the engine off for a second then started it back up and it was quiet again. Just seems strange to me.
I'm gonna go ahead and get a new tensioner and pray that it helps.
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Post by eaglerider on Mar 30, 2010 17:05:49 GMT -6
Get one for a real late model 500...they are much better - improved type.
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Post by anonigma on Apr 1, 2010 20:16:26 GMT -6
I took the old tensioner out and sure enough it was not working properly. May have been that I didn't hold the screw right when I put it in. I messed around and took it apart and I think I got working right again. But I had already order a new one from an '05 Vulcan 500. Should be here in a few days.
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