Wildguzzi.com
General Category => General Discussion => Topic started by: Mr Revhead on September 18, 2021, 11:32:18 PM
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Ok, so whilst having the bike apart for a few jobs (rear engine oil leak, wonky clutch etc) I decided now is a good time to replace the timing chain and tensioner. Bike is a 2003 EV at 80k kms and it's had a rear end leak from the day I had it (48ks) Also, I did an oil sample test earlier this year and it came back with an alert on high copper. :shocked:
After a bit of discussion as to what could cause that things to check were cam wear plate, bearings, rocker washers and head gasket pushrod seals.
There is no evidence of worn bearings, washers or pushrod wearing in the copper gaskets.
Today I got the chain out and tensioner off, there are distinct wear marks on the tensioner pad, and the beginning of witness marks in two places inside the casing, so definitely time to replace. Looking closely at the tensioner it's clear to see what looks like copper or brass impregnated throughout the substance the pad is made of. That would explain the test results.
(https://i.imgur.com/dEVI4Bd.jpg)
Now, I have found the Valtek tensioner does not fit the EV block due to the extra casting that sits behind the new style tensioner. It looks like this is there to support the tensioner as it sits hard against it. In searching for a solution I have found that Huzo had a similar issue with his Norge (https://wildguzzi.com/forum/index.php?topic=104650.0) There's a little difference between the two in that the EV doesn't have the tensioner locator pin imbedded in the casting.
This extra bit of casting sits out past the crank bearing plate, so the tensioner doesn't fit
I've looked at a couple of solutions so far including making spacers to make up the gap to the casting, but there isn't enough room for the bolts to clear the chain if you do that.
I've also thought about removing the pin from the Valtek and fitting it to the stock bracket, but the hole in the stock one is a lot bigger meaning you would need to fill in that hole, drill it, then fit the newer pin. You would also need to machine the Valtek pin down so the tensioner can line up with the chain.
I think the result is going to be grinding out that casting to fit the Valtek, however before I do that I'm going to see how much and how soon I can buy a new stock tensioner, it lasted 80ks and it'll take m a while to wear it out.
:gotpics:
You can see where the stock tensioner contacts the casting
(https://i.imgur.com/600MyAG.jpg)
Casting sticks out about the same as a bolt head
(https://i.imgur.com/CcvWfkK.jpg)
Tensioner pad won't line up even if I did manage to fit it spaced out.
(https://i.imgur.com/50C8yM6.jpg)
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I replaced the OEM tensioner on a VII Sport pretty much as you describe (chain starting to wear the case) with the Valtec one.
On another bike I think it was an EV but might have been a California II the original tensioner seemed to be doing a great job so I left it in there.