yes, Yes, YES!!! Oh crap, no, No, NO! KZ550 Timing Chain Adjuster mileage

So I finally sewed my courage together and tackled the timing chain adjuster on my 83 KZ550 A4. I've been avoiding this as replacing the chain and guides means moving my bike into the basement and a full teardown (if I'm going this far... not only that I won't have a way to test fire the bike without initiating WWIII with the missus...)

Here we go; Remove the cap and outer spring (has been obviously and purposely stretched) from the tensioner, outer wedge is protruding about 3/16". Remove the tank and hoses, remove the hardware for the battery box (factory air box still in use), slacken the intake carb boot clamps and pop the carbs out of the holders and up to create clearance to the upper cam chain adjuster bolt. Remove the two bolts (12" of 1/4" extension and a 10mm 1/4" wobble; drop out the rhs sidecover; run the ratchet in the sidecover opening). Pull out remnants of tensioner assembly. The two wedges have minor scars on the mating surfaces (can feel them with your fingernail; clean them up by spraying penetrating oil on 240 sandpaper and polish the marks away, finish with 600 grit. Replace the springs with new and assemble with Quaker State Golden Chassis Lube (EP2 Grease). Reassemble tensioner, there is some binding goin on, much better with grease (housing is clearly aluminum, the wedges are steel, 40000 Miles... (outer wedge protrudes ~ 7/16" out of tensioner) reassemble bike and test.

Oh, my, goodness. It fired on the first rotation. The sounds of lifter rattle uninterupted by cam chain rattle is majic to my ears! Take the bike for a brief jaunt (aka beat the snot out of it), still runs great, quiet as a mouse.

Put the bike away, assured my worries are over.

Pull the bike out on Sunday, fire it up... Oh Crap. It farts instead of fires. Choke choke choke, crank crank crank and it fires, unsteady... cleans up a little (rpm at 2500)... idle... cam chain rattle is BACK, not quite as loud but clear as day. Pull cap off of tensioner, outer wedge protrudes about 3/16".
no No NO!

Square one. I thought I really had something with polishing the wedges too.

Sooo, how many miles on your KZ/GPZ550 cam chain and guides? Is there any reason to believe that the Ape cam chain tensioner is not a viable repair here?

probably needs new cam chain. well its always something isnt it

Slightly over $50.00 and your problems are solved;)

Tease.

I hope you remembered to pack a few stickers in the box Jay. Thanks for the Click-N-Ship info.

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